description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
TECHNICAL FIELD
[0001] The present invention relates to photodetectors, and more particularly, to their protection against electrostatic discharge.
BACKGROUND OF THE INVENTION
[0002] Photodiodes or photodetectors including PINs and avalanche photodiodes (APDs) are widely used in fiberoptic and optical applications to convert received light into an electrical current signal. The photodiodes require a fast response time to be able to operate in high speed data transmission systems.
[0003] Photodiodes with a fast response time as used in such high speed signal transmission are especially vulnerable to damage from electrostatic discharge (ESD). The susceptibility of an electronic component to ESD is measured in terms of an ESD threshold. The higher the threshold, the more robust the component is against damage.
[0004] Typically the bandwidth of a photodiode is limited by the product of its capacitance and series resistance, known as its RC constant. In most photodiodes the capacitance of the p-n junction or junction capacitance is the main contributor to the total capacitance. Thus, to achieve a high bandwidth, it is necessary to reduce the junction capacitance by making the photodiode active area as small as possible.
[0005] However, in general, the ESD threshold is proportional to the size of the active area. The smaller the active area, the lower the ESD threshold and the more vulnerable is the photodiode to ESD damage. For photodiodes with a speed capability above 2.5 Gbps, the typical ESD threshold is below 50 Volt. The low ESD threshold is a very serious issue to photodiode manufacturing. It results in a low assembly yield even when high cost ESD protection equipment and procedures are implemented.
[0006] FIG. 1 a is a plan view of the schematic structure of a typical p-i-n photodiode 100 fabricated as a chip from a wafer substrate. In III-V compound semiconductor systems, such as indium phosphide (InP), indium gallium arsenide (InGaAs), gallium arsenide (GaAs) and similar, the p-i-n structure is epitaxially grown on either n-doped or semi-insulating substrate. For operation at wavelengths of interest to fiberoptic telecommunications, InP is a preferred substrate material.
[0007] A p-region 1 with periphery 1 a is formed by a localized p-type dopant diffusion process through a diffusion mask. Typically zinc (Zn) is used as the p-type dopant. The surface of the p-i-n photodiode 100 is passivated with a dielectric insulating layer 5 , typically silicon nitride (SiN x ).
[0008] To make a contact with the anode of the photodiode, an annular metal contact ring 2 is deposited through an annular opening or via 6 in the insulating layer 5 inside the periphery of the p-region 1 . The metal contact ring 2 is annular to permit optical light signals 8 to enter from the front of the photodiode 100 . The width of the metal contact ring 2 is made as small as possible to maximize the optically sensitive area of the photodiode 100 , which corresponds to the inner diameter of the metal contact ring 2 . Titanium/platinum/gold (Ti/Pt/Au) is a suitable metal combination for the metal contact ring 2 .
[0009] A bond pad 3 for making an external connection to the photodiode anode with a wire bond is deposited on the dielectric insulating layer 5 , connected to the metal contact ring 2 by a metal connecting link 4 . Arrows A-A′ indicate the location of a cross-section of the photodiode shown in FIG. 1 b.
[0010] With reference to FIG. 1 b, in the p-i-n photodiode 100 an InP substrate 10 supports an n-type layer structure comprising a n-doped InP buffer layer 11 0.3-1.0 μm thick, an unintentionally doped InGaAs absorption layer 12 0.8-4 μm thick, and a n-doped or unintentionally doped InP window layer 13 . A p-n junction 1 b is formed in the absorption layer 12 by the localized p-type dopant diffusion process to form the p-region 1 .
[0011] The metal contact ring 2 is generally deposited on a thin highly-doped p-type InGaAs layer 7 to lower the contact resistivity, thereby reducing the photodiode series resistance.
[0012] A contact to the cathode of the photodiode (not shown) is usually deposited on the bottom of the InP substrate 10 in the case where it is of a conducting n-type. Alternatively, if the InP substrate 10 is semi-insulating, a cathode connection can be made to the n-type layers from the top of the photodiode.
[0013] Photodiode structures have been disclosed in prior art that aim at increasing the ESD threshold.
[0014] Derkits, Jr. et al. (U.S. Pat. No. 6,835,984 “ESD resistant device”) disclose a semiconductor device such as a photodetector electrostatic discharge (ESD) protection structure. A dielectric layer is disposed on the active region layer, and a metal active region contact is disposed in the dielectric layer above the active region and electrically contacting the active region. An annular metal guard ring constituting the ESD protection structure is disposed in the dielectric layer around the active region contact, wherein the ESD protection structure electrically contacts the active region layer of the substrate to provide an ESD discharge path for charge on the surface of the dielectric layer.
[0015] While the metal guard ring provides a means for discharging surface charge on the larger surface portion of the dielectric layer, it does not provide direct ESD protection for the photodiode anode.
[0016] Maoyou Sun and Yicheng Lu have proposed a guard ring structure to improve the ESD threshold of an InGaAs photodiode in a paper “Nonlinearity in ESD robust InGaAs p-i-n photodiode” published in Electron Devices, IEEE Transactions on, vol. 52, Issue 7, pp 1508-1513, 2005. However, the guard ring increases the overall photodiode capacitance which tends to reduce the photodiode bandwidth and linearity.
[0017] It is an object of the invention to provide a photodiode structure with an improved ESD damage threshold by lowering the ESD induced current density.
[0018] A further object of the invention is to achieve a lower ESD-induced current density by providing a local widening of the ring contact at the intersection of the connection to the bond pad, incorporating a low conductivity layer to promote lateral current spreading and increasing the series resistance of the photodiode by increasing the contact resistivity of the anode contact.
SUMMARY OF THE INVENTION
[0019] A photodiode with an increased ESD threshold is disclosed, comprising an n-type InP buffer layer supported on an upper surface of an InP semiconductor substrate, an intrinsic InGaAs absorption layer on the buffer layer for absorbing light incident on the top surface of the photodiode, an InP window layer on the absorption layer for transmitting the incident light to the absorption layer, and a SiN x dielectric layer on the window layer for providing passivation.
[0020] A circular p-type region extending from a top surface of the window layer into the absorption layer forms a p-n junction therein, with an annular metal contact on the window layer within the periphery of the circular p-type region for making a contact with the p-type region through a contact region. A bond pad on the dielectric layer is provided, remote from the p-type region, for making an external connection to the photodiode, and a metal link connects the bond pad to the annular metal contact.
[0021] The contact region comprises an annular section and an expanded section at the intersection of the metal link and the annular metal contact. The expanded section has an area at least twice that of the annular section of the contact region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will be described in greater detail with reference to the accompanying drawings which represent preferred embodiments thereof, wherein:
[0023] FIGS. 1 a and 1 b are a top view and a schematic cross-section, respectively, of a prior art conventional p-i-n photodiode;
[0024] FIGS. 2 a and 2 b are EBIC and SEM images, respectively, of ESD damage to a photodiode at the intersection area of the contact ring and the connecting link to the bond pad;
[0025] FIGS. 3 a and 3 b are schematic cross-sections of a p-i-n photodiode according to the present invention with Ti/InGaAs and AuZn/InP contact interfaces, respectively;
[0026] FIG. 4 is a schematic cross-section of a p-i-n photodiode incorporating a current spreading layer according to the present invention;
[0027] FIGS. 5 a and 5 b are a top view and a schematic cross-section, respectively, of a p-i-n photodiode according to the present invention, which incorporates a via widening at the intersection of the contact ring and the connection to the bond pad; and
[0028] FIGS. 6 a and 6 b are a top view and a schematic cross-section, respectively, of a p-i-n photodiode according to the present invention, which incorporates a contact layer widening at the intersection of the contact ring and the connection to the bond pad.
DETAILED DESCRIPTION
[0029] A top-entry or front-entry photodiode structure is disclosed which overcomes the shortcomings of prior art devices mentioned above while achieving an improved higher electrostatic discharge (ESD) threshold. The photodiode may be a PIN, an APD or similar photodetector.
[0030] Experiments have shown that the ESD damage is typically localized at the intersection of the remote anode bond pad 3 and the contact ring 2 where a current pulse is injected during an electrostatic discharge event. FIG. 2 a shows an example where ESD damage 20 is evident in an electron beam induced current (EBIC) image taken in a scanning electron microscope (SEM), as well as a conventional SEM surface image ( FIG. 2 b ) of the same area. A high current density generated by the ESD current pulse leads to localized melting and subsequent recrystallization of the semiconductor underneath the contact ring 2 . This damage results in a high leakage current which compromises the operation of the device.
[0031] A low contact resistance and small contact area enhance the speed of the photodiode 100 , but also lead to localized high current density, especially at the intersection of the remote anode bond pad 3 and contact ring 2 . Therefore, an effective way to improve the ESD resistance is to reduce the peak current density.
[0032] According to the present invention, structural details for reducing the high current density generated by the ESD current pulse are disclosed. Basically, the peak current density can be reduced by incorporating in a photodiode one or more of the following:
(1) a high contact resistance metallization; (2) a separate current spreading layer; and (3) a locally increased contact area.
To improve the ESD threshold of a photodiode, these structural details may be incorporated either separately or in combination.
[0036] A first embodiment of a p-i-n photodiode 200 is shown as a cross-section in FIG. 3 a.
[0037] The p-i-n photodiode 200 a substrate 10 supports an n-type layer structure comprising a n-doped buffer layer 11 0.3-1.0 μm thick, an unintentionally doped absorption layer 12 0.8-4 μm thick, and a n-doped or unintentionally doped window layer 13 . The window layer 13 may comprise a lowly doped p-type semiconductor layer with a p-doping level less than 1×10 17 cm −3 . Alternatively, it may comprise a compensated layer with high resistance, such as a grown-in n-type layer with a doping level in the range 1×10 17 to 5×10 17 cm −3 . As the doping of this n-type layer is just slightly lower than the p-doping produced through a p-region diffusion process, it becomes a compensated layer after the p-region diffusion.
[0038] A p-n junction 1 b is formed in the absorption layer 12 by a localized p-type dopant diffusion process to form the p-region 1 with periphery 1 a. Typically zinc (Zn) is used as the p-type dopant for diffusion. Within the diffused p-region 1 , the incipient doping of the window layer 13 and of an upper portion of the absorption layer 12 becomes p-type doped. Outside the diffused p-region 1 , the doping of the window layer 13 and of an the absorption layer 12 remains essentially unchanged.
[0039] The surface of the p-i-n photodiode 200 is passivated with a dielectric insulating layer 5 , typically silicon nitride (SiN x ).
[0040] In III-V compound semiconductor systems, such as indium phosphide (InP), indium gallium arsenide (InGaAs), gallium arsenide (GaAs) and similar, the p-i-n structure is epitaxially grown on either n-doped or semi-insulating substrate. For operation at wavelengths of interest to fiberoptic telecommunications, InP is a preferred material for the substrate 10 .
[0041] For the same applications, InP is generally used for the buffer layer 11 and the window layer 13 . To absorb the optical wavelengths of interest, the absorption layer 12 is preferably InGaAs.
[0042] To make a contact with the anode of the photodiode, an annular metal contact ring 2 is deposited through an annular opening or via 6 in the insulating layer 5 inside the periphery of the p-region 1 . The metal contact ring 2 is annular to permit optical light signals 8 to enter from the front of the photodiode 200 . The width of the metal contact ring 2 is made as small as possible to maximize the optically sensitive area of the photodiode 200 , which corresponds to the inner diameter of the metal contact ring 2 . Titanium/platinum/gold (Ti/Pt/Au) is a suitable metal combination for the metal contact ring 2 .
[0043] A bond pad 3 for making an external connection to the photodiode anode with a wire bond is deposited on the dielectric insulating layer 5 , connected to the metal contact ring 2 by a metal connecting link 4 .
[0044] For lower contact resistivity and a reduced series resistance in the photodiode 200 , the metal contact ring 2 may make electrical contact to a thin contact layer 7 deposited on top of the window layer 13 . Titanium/platinum/gold is a suitable metal system for the metal contact ring 2 .
[0045] In InP-based devices generally p-type InGaAs is used for the contact layer 7 . In typical prior art contact schemes, the Ti/Pt/Au deposited on the p-type InGaAs contact layer 7 is highly doped (greater than 5×10 18 cm −3 ) to form an ohmic Ti/InGaAs interface with the metal contact ring 2 . For this purpose, the achievable contact resistivity is smaller than 1×10 −5 ohm cm 2 . While such a contact is good for device speed, it not good for lateral current spreading.
[0046] However, in this embodiment, the contact resistivity of the metal contact ring 2 is modified in such a way as to maintain a sufficiently low contact resistance to achieve a high speed operation capability of the p-i-n photodiode 200 , but high enough for good lateral spreading of electrical current.
[0047] Accordingly, the contact resistivity is increased to a range between 1×10 −4 and 5×10 −4 ohm cm 2 . This may be achieved in a number of ways, as illustrated in the following examples.
[0048] For the photodiode 200 in FIG. 3 a, the contact ring 2 made of Ti/Pt/Au connects to the p-region 1 through the contact layer 7 which has a low doping level that is less than 2×10 18 cm −3 .
[0049] A contact to the cathode of the photodiode (not shown) is usually deposited on the bottom of the InP substrate 10 in the case where it is of a conducting n-type. Alternatively, if the InP substrate 10 is semi-insulating, a cathode connection can be made to the n-type layers outside the p-region 1 on top of the photodiode 200 , for instance the window layer 13 or the contact layer 7 .
[0050] In a second embodiment, the photodiode 300 in FIG. 3 b has the contact ring 2 directly contacting the InP window layer 13 within the p-region 1 . For this purpose a gold-zinc (AuZn) layer 16 is substituted for the contact layer 7 of the previous embodiment. While the AuZn layer 16 forms an inferior ohmic contact to the InP window layer 13 , it will be sufficiently good for high speed operation of the photodiode.
[0051] In a third embodiment, the photodiode 400 in FIG. 4 the window layer 13 of the previous embodiments is subdivided into a lower window layer 13 , a current spreading layer 14 and an upper window layer 15 . The lower and upper window layers 13 and 15 are either undoped or slightly n-doped to a level of 1×10 16 to 5×10 16 cm −3 to reduce a dark current of the photodiode 400 .
[0052] In order to promote a lateral spreading of electrical current flowing from the contact ring 2 toward the buffer layer 11 , the current spreading layer 14 is doped higher than the lower and upper window layers 13 and 15 . For the current spreading layer 14 , the doping level should be in the range of 1×10 17 to 5×10 17 cm −3 , while the thickness should be about 0.2 to 0.5 micron.
[0053] To form the p-n junction 1 b in the absorption layer 12 , the localized p-type dopant diffusion (using, for instance, Zn) extends through the upper window layer 15 , the current spreading layer 14 and the lower window layer 13 . Within the diffused p-region 1 , the incipient doping of the lower and upper window layers 13 and 15 , the current spreading layer 14 and an upper portion of the absorption layer 12 becomes p-type. Outside the diffused p-region 1 , the doping of the lower and upper window layers 13 and 15 , the current spreading layer 14 and an upper portion of the absorption layer 12 remains essentially unchanged.
[0054] The metal contact ring 2 makes electrical contact to the thin contact layer 7 deposited on top of the window layer 15 . P-type InGaAs with a doping level greater than 5×10 18 cm −3 can be used for the contact layer 7 in conjunction with Ti/Pt/Au for the metal contact ring 2 .
[0055] A fourth embodiment is shown in FIG. 5 a. The structure of photodiode 500 is similar to the previous embodiments, however with an important difference. At the intersection of the annular metal contact ring 2 and the metal connecting link 4 , the via 6 through the passivation layer 5 is locally expanded to form an enlarged via intersection region 6 ′. In this case, the contact layer 7 may retain an annular shape with a constant width of the annulus. Although the via intersection region 6 ′ is shown to have a square shape, other shapes may be used, bearing in mind that shapes with smooth or round edges are preferred to avoid high electric field concentrations.
[0056] Increasing the area of the via intersection region 6 ′ can effectively reduce the current density at this most vulnerable location of the contact ring 2 of the photodiode 500 . The via intersection region 6 ′ is dimensioned to have an area which is two or more times larger than the area of the unexpanded via 6 . Arrows B-B′ indicate the location of the cross-section of the photodiode 500 shown in FIG. 5 b.
[0057] A variation of this embodiment may be combined with the second embodiment, where the contact layer 7 is omitted and the metallization of contact ring 2 is changed from Ti/Pt/Au to AuZn in order to increase the contact resistivity of the metal contact ring 2 .
[0058] Alternatively, the p-doping level of the contact layer 7 may be also be lowered to increase the contact resistivity of the metal contact ring 2 .
[0059] In FIG. 6 a a fifth embodiment is presented. The photodiode 600 is similar the fourth embodiment, except the via intersection region 6 ′ is replaced by a contact layer intersection region 7 ′, which is a local enlargement of the contact layer 7 at the intersection of the annular metal contact ring 2 and the metal connecting link 4 . The contact layer 7 may including the contact layer intersection region 7 ′ may consist of a p-doped InGaAs layer, which can be highly doped if a low contact resistivity is desired.
[0060] Analogous to the previous case, the via 6 through the passivation layer 5 may retain an annular shape with a constant width of the annulus.
[0061] Here also contact layer intersection region 7 ′ is shown to have a square shape, however other shapes may be used, preferably with smooth or round edges to avoid high electric field concentrations.
[0062] The contact layer intersection region 7 ′ is dimensioned to have an area which is two or more times larger than the area of the unexpanded contact layer 7 . Arrows C-C′ indicate the location of the cross-section of the photodiode 600 shown in FIG. 6 b. | A photodetector with an improved electrostatic discharge damage threshold is disclosed, suitable for applications in telecommunication systems operating at elevated data rates. The photodetector may be a PIN or an APD fabricated in the InP compound semiconductor system. The increased ESD damage threshold is achieved by reducing the ESD induced current density in the photodetector by a suitable widening of the contact at a critical location, increasing the series resistance and promoting lateral current spreading by means of a current spreading layer. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2004-137704 filed on May 6, 2004; the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a cutting edge apparatus used for tunnel excavation, and in particular to a cutting edge apparatus which facilitates driving of a cutting edge into a ground.
[0003] Conventionally, excavation for a tunnel with a relatively small diameter (a diameter up to about several meters) has been performed by workers' hand drilling. In this case, the cutting edge positioned at the distal end of a Hume pipe is propelled by a propelling apparatus such as a hydraulic jack to be driven into the ground. Workers drill the ground and remove soil produced from the cutting face of a tunnel to excavate a tunnel.
[0004] In the tunnel excavation, the cutting face may collapse. The collapse causes a large amount of soil to enter the cutting edge, thereby risking workers' safety and rendering working in front of the cutting edge difficult.
[0005] A cutting edge apparatus that ensures safe tunnel excavation even when there is a risk, such as collapse of a cutting face, has been proposed (see Japanese Patent Application Laid-open No. 2002-242584, for example).
[0006] In the cutting edge apparatus, the cylindrical outer pipe has a cutting edge to be driven into the ground at the distal end thereof. The outer pipe has a tapered conical main unit vibrated by a vibration motor therein. When the cutting face of the tunnel collapses, deposition of soil in the conical main unit allows for safe tunnel excavation, which is considerably effective for safety ensuring.
[0007] In the above structure, vibrations of the conical main unit caused by the vibration motor reduce friction between the conical main unit and fallen soil, thus easily correcting propelling and directionality of the cutting edge apparatus.
[0008] Furthermore, the cutting edge and the conical main unit are provided separately from each other for easy replacement of a worn cutting edge.
[0009] In the above structure, however, driving of the cutting edge into a firm ground requires a large force, and the structure should be further improved.
SUMMARY OF THE INVENTION
[0010] The aspect of the invention provides a cutting edge apparatus. The apparatus includes a cylindrical outer pipe to be driven into a ground. The apparatus includes a vibratable vibration cylinder provided within the outer pipe and being movable relative to the outer pipe in an axial direction of the outer pipe. The apparatus includes a cutting edge member substantially identical in outer size with the outer pipe and being integrally mounted to the outer circumference of the end of the vibration cylinder. The apparatus includes a vibrator mounted to the vibration cylinder and configured to vibrate the vibration cylinder. The vibration cylinder has a tapered rear portion so that the rear portion becomes smaller in size as the rear portion extends toward the rear end of the vibration cylinder.
[0011] The cutting edge member may have a distal end coated with a hard material.
[0012] The cutting edge apparatus may include a lubrication supplier configured to supply a lubricant to the outer pipe or the outer circumferential surface of a following pipe provided at the back of the outer pipe.
[0013] The cutting edge member may be fixed to the outer circumference of the end of the vibration cylinder.
[0014] The invention allows for excavation of a tunnel, vibrating the cutting edge member. This way facilitates driving of the cutting edge member into a ground. This way allows the tapered portion of the cutting edge member to receive the fallen soil during falling of the cutting face of the tunnel, thus ensuring safety.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0015] FIG. 1 is a sectional view of a cutting edge apparatus according to an embodiment of the invention;
[0016] FIG. 2 is a plan sectional view of the cutting edge apparatus shown in FIG. 1 ;
[0017] FIG. 3 is a right side view of the cutting edge apparatus and the following pipe as viewed from arrows III-A and III-B in FIG. 1 , where the left half as indicated by III-A illustrates the cutting edge apparatus, and the right half as indicated by III-B illustrates the following pipe; and
[0018] FIG. 4 is a schematic view illustrating excavation facilities using the cutting edge apparatus shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] With reference to FIG. 1 , a cutting edge apparatus 1 according to an embodiment of the invention includes a cylindrical outer pipe 5 driven in a ground 3 by a propelling apparatus such as hydraulic jacking cylinders 127 a and 127 b (see FIG. 4 ). The cutting edge apparatus 1 includes a vibration cylinder 7 mounted inside the outer pipe 5 to be movable in an axial direction of the outer pipe 5 and be capable of vibrating.
[0020] In more detail, the vibration cylinder 7 includes an inner pipe 11 supported within the outer cylinder 5 via an annular sealing member 9 to be movable in an axial direction and be capable of vibrating. The front end of the inner pipe 11 is integrally welded to a stopper ring 13 . The stopper ring 13 abuts against a stopper 15 provided on the inner face of the outer pipe 5 to restrict the vibration cylinder 7 to movement in a forward direction (the left direction in FIG. 1 ).
[0021] The front end of the stopper ring 13 is integrally fixed, by welding or the like, to the rear end of a taper ring 17 whose diameter gradually increases toward the front end thereof. The outer periphery of the front end of the taper ring 17 is integrally welded to a guide ring 19 with an outer diameter slightly smaller than the inner diameter of the outer pipe 5 . The guide ring 19 has an outer peripheral face projecting from the front end face (the left end face in FIG. 1 ) of the outer pipe 5 . The outer peripheral face is integrally welded to a ring-like cutting edge member 21 with an outer diameter approximately equal to that of the outer pipe 5 . The rear end face (a right end face in FIG. 1 ) of the cutting edge member 21 serves as an abutting face that is abutable relatively against the front end face of the outer pipe 5 . The rear end of the cutting edge member 21 and the front end of the outer pipe 5 have an allowance 20 therebetween.
[0022] That is, when the propelling apparatus pushes against the outer pipe 5 in a forward direction, the front end face of the outer pipe 5 and the rear end face of the cutting edge member 21 abut against each other to drive the cutting edge member 21 into the ground 3 . The step portion between the taper ring 17 and the guide ring 19 and the step portion between the guide ring 19 and the cutting edge member 21 are welded in a taper shape. The taper shape eliminates the step portion to allow for smooth driving of the cutting edge member 21 into the ground. The annular front end face of the cutting edge member 21 is coated with an appropriate hard material 23 having excellent wear resistance and impact resistance, such as alloy tool steel, high-speed steel, or hard metal by spraying.
[0023] The structure allows tunnel excavation even if the ground 3 is firm, and achieves a long life of the cutting edge member 21 .
[0024] The rear portion of the inner pipe 11 gradually decreases in diameter toward the rear end. The rear portion of the inner pipe 11 is integrally welded to a taper body 25 . The taper body 25 with a tapered cylindrical shape has a circular opening portion 25 a at the rear end portion, and the area of the opening portion 25 a is about a fourth (¼) of a circular area surrounded by the cutting edge member 21 . The opening portion 25 a with a small diameter of the taper body 25 is attached with a lid 29 to be openable and closable using a hinge 27 (see FIG. 2 ). The opening portion 25 a has a lock handle 31 (see FIG. 4 ) that locks the lid 29 to a closed state thereof.
[0025] The taper body 25 is vibratably supported to the outer pipe 5 by elastic members 33 such as rubbers provided at a plurality of portions on the inner peripheral face on the outer cylinder 5 . The taper body 25 is mounted with vibrators 35 such as vibration motors, which applies vibrations to the taper body 25 . The outer peripheral face of the taper body 25 has an abutting member 39 fixed thereon. The rear end portion of the abutting member 39 is abutable against the front face of a ring-like bracket 37 provided on the inner peripheral face of the outer pipe 5 .
[0026] A clearance 38 between the bracket 37 and the abutting member 39 is set to be approximately equal to a clearance 20 between the front end face of the outer pipe 5 and the rear end face of the cutting edge member 21 . When the outer pipe 5 and the cutting edge member 21 abut against each other to push forward (propel) the cutting edge member 21 , the bracket 37 abuts against the abutting member 39 to push forward the taper body 25 . That is, the cutting edge member 21 and the taper body 25 are integrally pushed forward in synchronization with each other. The structure disperses portions being pushed, while the cutting edge member 21 is being pushed forward by the outer pipe 5 , thereby suppressing stress.
[0027] The rear end of the outer pipe 5 has a following pipe 41 for propelling (pushing forward) the outer pipe 5 . In detail, the outer diameter of the following pipe 41 is slightly smaller than an outer diameter of the outer pipe 5 . The front end portion of the following pipe 41 abuts against an annular abutting member 43 provided on the inner peripheral face of the outer pipe 5 near the rear end thereof. The outer peripheral face of the distal end portion of the following pipe 41 and the inner peripheral face of the outer pipe 5 have an annular sealing member 45 made from rubber mounted therebetween.
[0028] The inner peripheral face of the following pipe 41 near the rear end has an annular distal end face abutting member 49 to be pushed forward by the distal end face of the Hume pipe 47 . The annular chamber 51 is formed at the front side (the left side in FIG. 1 ) of the distal end face abutting member 49 . The chamber 51 reserves lubricant. The inner peripheral face of the chamber 51 is formed with a plurality of supplying ports 53 for supplying lubricant. The inner peripheral face 51 has an inspection port 59 that is closed by a lid member 57 attachable or detachable by a fixing tool 55 such as a plurality of bolts.
[0029] The outer peripheral face of the following pipe 41 has an annular opening member 63 corresponding to the chamber 51 . The opening member 63 is provided with opening portions 61 (see FIG. 2 ) opened so as to be enlarged rearward and formed along a circumferential direction thereof at proper intervals. The outer peripheral face of the opening member 63 is covered with an annular cover 65 . The opening portions 61 have communication holes 67 opened to the following pipe 41 and communicating with the chamber 51 .
[0030] When lubricant such as oil is properly supplied from the supplying ports 53 into the chamber 51 , lubricant in the chamber 51 is supplied to the opening portions 61 so that lubricant is supplied on the outer peripheral face of the Hume pipe 47 through the opening portions 61 . Thereby, while the Hume pipe 47 is being pushed forward by a propelling apparatus such as a hydraulic jack, friction between the Hume pipe 47 and the ground 3 is made small, thereby facilitating pushing of the Hume pipe 47 . The condition of the lubricant in the chamber 51 is confirmed through the inspection port 59 . When, for example, lubricant has been consolidated, detachment of the lid member 57 permits the lubricant to be easily taken out of the chamber 51 .
[0031] In the structure, when the propelling apparatus pushes forward against the Hume pipe 47 , the Hume pipe 47 pushes against the following pipe 41 and the following pipe 41 pushes against the outer pipe 5 . When the outer pipe 5 is pushed forward, the distal end face (the front end face) of the outer pipe 5 abuts against the cutting edge member 21 to be pushed forward, thus driving the cutting edge member 21 into the ground 3 .
[0032] During the driving-into, when the vibrators 35 are driven to vibrate the taper body 25 , integral provision of the taper body 25 and the cutting edge member 21 allows integral vibrations thereof. Thereby, the cutting edge member 21 is driven while being vibrated to the ground 3 . Even if the ground 3 is firm, effective driving is allowed to improve efficiency.
[0033] When the cutting edge member 21 is driven into the ground 3 , the lid 29 is held in a closed state thereof, considering collapse of a cutting face of the ground 3 . After the cutting edge member 21 is driven into the ground 3 , the lid 29 is opened. The cutting edge member 21 then excavates the cutting face of the ground 3 in a surrounded state, thus excavating a tunnel.
[0034] After soil produced by excavation is ejected from the taper body 25 , the propelling apparatus drives the cutting edge member 21 into the ground 3 again. Repetition of this work continuously performs tunnel excavation.
[0035] As understood from the descriptions, the taper body 25 and the cutting edge member 21 integrally provided vibrate integrally. This vibration facilitates driving of the cutting edge member 21 into the firm ground 3 as compared with the conventional system. When a large amount of fallen soil is present inside the taper body 25 , the vibration reduces friction between fallen soil and the taper body 25 , thus facilitating directional correction of the cutting edge member 21 .
[0036] The coating of the hard material 23 on the distal end portion of the cutting edge member 21 enhances wear resistance and impact resistance, thereby, allowing for the long life in the cutting edge member 21 .
[0037] Further, the following pipe 41 has the lubricant supplying ports which supply lubricant to the outer peripheral face of the Hume pipe 47 , thus reducing friction occurring during pushing of the Hume pipe 47 forward.
[0038] The structure is applied to the outer pipe 5 , and the lubricant supplying ports may be provided in the outer pipe 5 .
[0039] With reference to FIG. 4 , excavation facilities 100 to which the cutting edge apparatus 1 is applied will be described.
[0040] The excavation facilities 100 include a cutting edge apparatus 1 which excavates the ground 3 . The excavation facilities 100 include a jacking pipe 101 serving as a Hume pipe 47 communicating with the cutting edge apparatus 1 . The end of the jacking pipe 101 projects above the pit floor 121 within a pit 113 . The excavation facilities 100 include a battery feeder 103 feeding power to the vibrators 35 . The excavation facilities 100 include a compressed air-mixer 105 and a flexible pipe 107 connected to the compressed air-mixer 105 in the jacking pipe 101 . The excavation facilities 100 include a vacuum pump 109 connected to the flexible pipe 107 . Soil produced by excavation is conveyed by a truck 111 .
[0041] The excavation facilities 100 include an adapter 123 mounted at the end of the jacking pipe 101 in the pit 113 . The excavation facilities 100 include a reaction wall 125 provided on the side wall of the pit 113 . The excavation facilities 100 include jacking cylinders 127 a and 127 b serving as a propelling apparatus arranged between the reaction wall 125 and the adapter 123 .
[0042] The excavation facilities 100 include a generator 131 and a power pack 133 for supplying power to the battery feeder 103 . The excavation facilities 100 include, outside the pit 113 , a lubrication pump 135 serving as a lubricant supplying section, which supplies lubricant to the jacking pipe 101 . A hydraulic crane 137 which conveys, for example, jacking pipes 101 , is put on standby outside the pit 113 .
[0043] A method of operating the excavation facilities 100 will be described.
[0044] When the jacking cylinders 127 a and 127 b push against the jacking pipe 101 forward, the jacking pipe 101 pushes against the outer pipe 5 of the cutting edge apparatus 1 to drive the cutting edge member 21 into the ground 3 . During the driving-into, the lubrication pump 135 supplies lubricant to the outer face of the jacking pipe 101 .
[0045] The generator 131 supplies power to the vibrators 35 via the battery pack 133 and the battery feeder 103 . The vibrators 35 vibrate the cutting edge member 21 as well as the vibration cylinder 7 . The cutting edge member 21 excavates a tunnel in the ground 3 .
[0046] Soil produced by excavation is sucked up on a ground via the flexible pipe 107 by the vacuum pump 109 , and it is loaded on the truck 111 .
[0047] When the cutting edge apparatus 1 goes into the ground 3 at a fixed distance, a new jacking pipe is hung down in the pit 113 by the hydraulic crane 137 . The new jacking pipe is set to the end of the jacking pipe 101 in use.
[0048] Although the invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the above teachings. The scope of the invention is defined with reference to the following claims. | A cutting edge apparatus includes a cylindrical outer pipe to be driven into a ground. The apparatus includes a vibratable vibration cylinder provided within the outer pipe and being movable relative to the outer pipe in an axial direction of the outer pipe. The apparatus includes a cutting edge member substantially identical in outer size with the outer pipe and being integrally mounted to the outer circumference of the end of the vibration cylinder. The apparatus includes a vibrator mounted to the vibration cylinder and configured to vibrate the vibration cylinder. The vibration cylinder has a tapered rear portion so that the rear portion becomes smaller in size as the rear portion extends toward the rear end of the vibration cylinder. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ink-jet printer and a control method thereof, and more particularly, to an ink-jet printer which can be operated by power supply from, e.g., either a rechargeable secondary battery or a power supply unit of converting a commercial power source into a DC power source, acting as an operation power source, and a power control method thereof.
2. Related Background Art
In recent years, various electronic apparatuses such as a portable personal computer, a portable telephone, a video camera, a portable printer and the like have appeared on the market.
These electronic apparatuses are downsized in consideration of portability, and can be used in a state, i.e., a cordless state, being not connected to a household power source.
Therefore, each of these electronic apparatuses is constituted to be able to be used without connecting it to the household AC power source through a power cord, in such a way that a battery is built into the electronic apparatus or a unit such as a battery pack having a battery built-in is externally connected to the electronic apparatus.
As the power source to be used for these electronic apparatuses, a rechargeable battery, i.e., a so-called secondary battery, is frequently used. Here, as the secondary batteries, a nickel-cadmium battery, a nickel-hydrogen battery, a lithium-ion battery and the like are known.
On one hand, an external power supply unit (generally called an AC adapter) of converting the AC power source into a DC power source can be connected to the electronic apparatus so that it can be operated also based on the AC power source in a house, an office or the like. Also, a current to charge the secondary battery is supplied from the AC adapter.
The secondary battery is generally charged in a case where the AC power source connected to the electronic apparatus is turned on and the electronic apparatus has electric power in reserve because it does not perform high-current driving such as a mechanical operation or the like, or in a case where the electronic apparatus is in a power-off state.
Therefore, even while the electronic apparatus is not powered, if the AC adapter is being connected to the electronic apparatus, it is necessary to be able to automatically charge the secondary battery without any user's operation.
For this reason, in the case where the above electronic apparatus is not powered, the structure to shut off the power from the AC power source to the AC adapter by a mechanical switch is not adopted generally. Instead, even when the electronic apparatus is not powered, the power is supplied to the electronic apparatus to operate a built-in MPU (microprocessor unit), whereby on and off states of the power switch of the electronic apparatus are always detected.
In such a structure, to decrease power consumption while the power switch is turned off, generally, clock frequencies of the MPU and a control circuit for controlling the electronic apparatus are decreased as compared with the case where the power switch is turned on, or the clock frequencies are stopped.
However, in the above conventional case, although the lower consumption as above is achieved, it is still necessary to supply the power to a logic circuit including the MPU of the electronic apparatus, whereby it is not avoided that the electronic apparatus consumes the electric power more than a certain value.
Moreover, the AC adapter consumes the electric power of about 0.3 W to 0.5 W even in an unloaded state that the electronic apparatus is not powered, and the power consumption tends to increase with accelerating speed if the electronic apparatus performs some operation.
Therefore, in order to suppress the power consumption to about 0.5 W and below in the state that an overall system including the AC adapter and the electronic apparatus is not powered, it is necessary to set the power consumption of the electronic apparatus to substantially “0” while it is not powered. If it pays attention to the current state that reactive power while the electronic apparatus is not powered becomes a problem due to recent concern about energy saving and tighter regulations, it is demanded to further decrease the power consumption.
SUMMARY OF THE INVENTION
In order to solve the above problem, an ink-jet printer according to the present invention is the ink-jet printer including a control circuit for controlling a recording operation by receiving power supply from an AC adapter acting as a power supply means, and comprising: a voltage output circuit for outputting a voltage on the basis of a signal output by the power supply means; and a voltage output control circuit for turning on and off the voltage output circuit, wherein, in case of starting the power supply from the AC adapter, the voltage output control circuit sets the output of the voltage output circuit to an off state after setting the output to an on state for a certain period of time.
A control method for the ink-jet printer according to the present invention is the control method for the ink-jet printer which performs the recording operation by receiving the power supply from the AC adapter acting as the power supply means, comprising: a voltage output step of outputting a voltage by the voltage output circuit, on the basis of the signal from the power supply means; an output step of outputting a control signal to turn on and off the voltage output circuit; and a control step of controlling, in case of starting the power supply from the AC adapter, the output step to output the control signal to turn on the voltage output circuit for a certain period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a printer;
FIG. 2 is a block diagram showing the structure of a control circuit of the printer;
FIG. 3 is a block diagram showing the structure of a power supply unit of the printer according to the first embodiment;
FIG. 4 is a timing chart showing main signals of the control circuit when an AC adapter is connected;
FIG. 5 is a timing chart showing the main signals of the control circuit when a power switch is turned on and off;
FIG. 6 is a flow chart showing a control procedure of an MPU according to the first embodiment;
FIG. 7 is a block diagram showing the structure of a power supply unit of the printer according to the second embodiment; and
FIG. 8 is a flow chart showing a control procedure of an MPU according to the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is an external perspective view showing a portable ink-jet printer (hereinafter called a printer) 1 according to the typical embodiment of the present invention. The printer is shown as having the structure capable of performing both color printing and black and white color (monochrome) printing. If the printer is considered as a black and white color (monochrome) printing dedicated device, it has the structure that only an ink cartridge containing black ink explained later is mounted on a recording head.
As shown in FIG. 1 , a multi-nozzle recording head 102 having 128 nozzles and a cartridge guide 103 are mounted on a carriage 101 , and the recording head 102 discharges a black (K) ink, or cyan (C), magenta (M) and yellow (Y) inks respectively. When the printer performs a recording operation, an ink cartridge 110 containing the black ink and an ink cartridge 111 containing the other three kinds of color inks are being mounted on the recording head 102 , whereby the cyan (C), magenta (M), yellow (Y) and black (K) inks are supplied from the respective ink cartridges, and driving signals for the respective nozzles of the recording head 102 are supplied through a flexible cable (not shown) on which numerous conductive wires are arranged.
On one hand, the carriage 101 is mounted on two guide rails 104 and 105 , whereby the carriage 101 is reciprocated in the X direction (hereinafter called a main scan direction) according to that an endless belt 109 connected to the carriage 101 is driven by a carrier motor (later described). Moreover, a recording sheet 106 is stretched by auxiliary rollers 107 so that the recording sheet 106 can be smoothly conveyed, and a conveyance roller 108 is driven by a conveyance motor (later described) to feed the recording sheet 106 in the Y direction (hereinafter called a sub scan direction).
FIG. 2 is a block diagram showing the structure of a control circuit in the printer. In FIG. 2 , numeral 170 denotes an interface through which data is input from an external device such as a host computer or the like, numeral 171 denotes an MPU (microprocessor unit), numeral 172 denotes a ROM which stores control programs (including character fonts, if necessary) to be executed by the MPU 171 , and numeral 173 denotes a DRAM which temporarily stores various data (control parameters, recording data, etc.).
Numeral 174 denotes a gate array (G.A.) which controls recording data supply to the recording head 102 and further controls the data transfer among the interface 170 , the MPU 171 and the DRAM 173 . Numeral 179 denotes a carrier motor which moves the recording head 102 in the main scan direction, numeral 178 denotes a conveyance motor which conveys the recording sheet, numeral 175 denotes a head driver which drives the recording head 102 , and numerals 176 and 177 denote motor drivers which respectively drive the conveyance motor 178 and the carrier motor 179 .
Next, the outline of the operation of the above control circuit will be explained. If a recording signal is input to the interface 170 , the input recording signal is converted into recording data for printing between the gate array 174 and the MPU 171 . Thus, the motor drivers 176 and 177 are respectively driven, and the recording head 102 is driven according to the recording data transferred to the head driver 175 , whereby a recording operation is performed.
Here, it should be noted that the portable ink-jet printer is explained as a typical example of the electronic apparatus. However, in addition to the ink-jet printer, the present invention is applicable to electronic apparatuses such as a laptop personal computer, a palmtop personal computer, a digital video camera, an Internet-accessible personal digital assistance and the like capable of operating by the secondary battery or the AC power source.
<First Embodiment>
FIG. 3 is a block diagram showing the detailed structure of a control unit 1 of the printer (also called the printer 1 hereinafter).
Numeral 2 denotes an AC adapter which converts an AC power source from a household outlet or the like into a DC power source and supplies power to the control unit 1 of the printer, and numeral 3 denotes a secondary battery which supplies power to the control unit 1 of the printer. When only the secondary battery 3 is connected to the printer, the power is supplied to the control unit 1 through a line 1 a , a charging control circuit 10 and a line 1 b in due order.
On one hand, when the AC adapter 2 is connected to the control unit 1 of the printer, the power is supplied from the AC adapter 2 irrespective of whether or not the secondary battery 3 is connected. That is, an AC voltage from an AC power source 1 c is converted into a DC voltage by the AC adapter 2 , and the converted DC voltage is input through a line 1 d . In the present embodiment, it is assumed that the DC voltage has the value of, e.g., 16V. The voltage supplied from the secondary battery 3 or the AC adapter 2 through the line 1 d is stepped down to a predetermined voltage (e.g., 5V) by a DC-DC converter 4 , and the stepped-down voltage is supplied as a logic operation voltage V CC of the control unit 1 of the printer.
The voltage supplied from the secondary battery 3 or the AC adapter 2 through the line 1 d is likewise input to a DC-DC converter 13 and stepped up to a predetermined voltage (e.g., 19V), and the stepped-up voltage is supplied as a driving voltage V H for the motor and the recording head of the printer.
In a case where the secondary battery 3 is connected and not in a full-charged state, and there is room in the power consumption of the printer, the battery is charged through the AC adapter 2 and the charging control circuit 10 .
Here, it should be noted that the secondary battery is a rechargeable battery of Ni—Cd system, lithium-hydrogen system of the like such as a nickel-cadmium battery, a nickel-hydrogen battery, a lithium-ion battery or the like.
Next, the structure of the printer 1 and an on/off sequence of the power source will be explained in detail with reference to FIGS. 4 and 5 being the timing charts of the main signals shown in FIG. 3 .
As shown in FIG. 3 , a power switch 17 for turning on/off the printer is provided in the control unit 1 of the printer, and an output signal if from the power switch 17 is read by the MPU 171 through an input port 18 , and it is controlled based on an output signal 1 g from an output port 19 to turn on/off a transistor 20 .
First, if the AC adapter 2 is connected to the printer 1 in the state that it is connected to the outlet of the AC power source, the input voltage rises on the line 1 d (of course, the input voltage rises on the line 1 d even if the AC adapter is connected to the outlet of the AC power source in the state it is connected to the control unit 1 of the printer). Here, since the power switch 17 is not depressed, the printer is in the state that the power source is not turned on based on the on state of the power switch.
The signal on the line 1 d is input to the DC-DC converter 4 , and the line 1 d is connected to one end of a resistor R 1 . The other end of the resistor R 1 is connected to an output control terminal 30 of the DC-DC converter 4 , and a capacitor C 1 is inserted between the resistor R 1 and the ground.
The output control terminal 30 of the DC-DC converter 4 comes to be in a state of capable of oscillating at “L” level, and the logic operation voltage V CC comes to be in an output state. On the other hand, the output control terminal 30 comes to be in a state of incapable of oscillating at “H” level, and the logic operation voltage V CC comes to be in an output-off state.
An integration circuit is composed by the resistor R 1 and the capacitor C 1 , and an input signal 1 h of the output control terminal 30 of the DC-DC converter 4 gradually rises from 0V at a time constant determined according to the resistor R 1 and the capacitor C 1 .
After the DC voltage on the line 1 d rose, the input signal 1 h of the output control terminal 30 is recognized as “L” level for a certain period of time, whereby the power is supplied from the DC-DC converter 4 to the logic circuit including the MPU while the signal is being “L” level.
After then, as shown in FIG. 4 , since the input signal 1 h of the output control terminal 30 is recognized as “H” level when it comes to have a regulated voltage or more, the DC-DC converter 4 stops oscillating, whereby the output voltage V CC from the DC-DC converter 4 becomes 0V.
Therefore, before the output control terminal 30 is recognized as “H” level, the MPU 171 of which the reset state is released by receiving the power supply outputs the signal 1 g of “H” level from the output port 19 to turn on the transistor 20 , whereby the output control terminal is set as “L” level, and the operation state of the MPU 171 is maintained.
After then, the MPU 171 checks through the charging control circuit 10 whether or not it is necessary to charge the secondary battery 3 . This check is performed by flowing the charging current to the secondary battery and measuring the value of the flown current. If it is necessary to charge the secondary battery 3 , a current of predetermined magnitude flows, while if it is unnecessary to charge the battery, only a little current flows.
If it is unnecessary to charge the secondary battery 3 because it is in the full-charged state, the MPU 171 outputs the signal 1 g of “L” level from the output port 19 to turn off the transistor 20 . Then, if the transistor 20 is turned off, the potential 1 h increases according to a time constant of the integration circuit composed of the resistor R 1 and the capacitor C 1 , and the DC-DC converter 4 stops oscillating at the time when the output control terminal 30 comes to have the regulated voltage or more. As a result, the output voltage V CC becomes 0V, and the logic circuit stops operating, whereby the power consumption of the printer becomes approximately zero.
Incidentally, in FIG. 3 , a diode D 2 and a resistor R 3 together function to discharge electrical charges on the capacitor C 1 through the line of the plus terminal of the capacitor C 1 →the diode D 2 →the resistor R 3 →the minus terminal of the capacitor C 1 , when the output connector of the external supply unit (AC adapter) 2 is pulled out.
Moreover, this discharge circuit can connect the cathode of the diode D 2 to the output V CC being the output line of the DC-DC converter 4 without using the resistor R 3 , and thus discharge the electrical charges by using an impedance of the device.
Next, the circuit operation that a user depresses the power switch 17 in this state to again supply the power to the printer and operate it will be explained with reference to the timing chart shown in FIG. 5 .
Before the start (i.e., the depression of the power switch 17 ) of the timing chart shown in FIG. 5 , although the power is supplied from the AC adapter up to the line 1 d , the DC-DC converter 4 stops oscillating, whereby the logic circuit does not operate because the output voltage V CC is 0V.
In this state, if the user depresses the power switch 17 to operate the printer, the potential on the signal line 1 h becomes about 0.6V through a diode D 1 because one end of the power switch 17 is grounded. Thus, the output control terminal 30 is recognized as “L” level, the DC-DC converter 4 starts oscillating, and the logic voltage V CC is supplied to the logic circuit including the MPU 171 .
Then, if the logic power source voltage V CC becomes a certain level or more, a reset circuit 21 outputs a rest signal 1 j of “L” level for a predetermined period of time T (about 100 msec) to reset the MPU 171 . After this reset operation ends and the reset is released, the MPU 171 executes the control program stored in the ROM 172 to control the printer 1 .
In the initial control according to the control program stored in the ROM 172 , the output port 19 outputs the signal 1 g of “H” level to turn on the transistor 20 . By this operation, since the potential of the signal 1 h is maintained as “L” level after the depression of the power switch 17 ends, the DC-DC converter 4 comes to be in the output state, and the state that the power is supplied is maintained, whereby the printer 1 comes to be in the operation state.
Next, a circuit operation from the operation state of the printer 1 , i.e., the state that the power is being supplied from the AC adapter 2 to the internal circuit of the printer 1 through the DC-DC converter 4 , to the state that the power supply to the printer 1 is interrupted by the depression of the power switch 17 and thus the printer 1 comes to be in the power off state will be explained.
First, in the state that the power is supplied from the power supply unit (AC adapter) 2 to the printer 1 , the potential of the signal 1 h is maintained as about 0.6V because the transistor 20 is kept on through the output port 19 as described above.
In this state, if the power switch 17 is depressed and subsequently released, a pulse P as shown in FIG. 5 is output to the power switch output signal if and then input to the input port 18 .
On one hand, if it is detected through the input port 18 that the power switch 17 is depressed, then the MPU 171 starts a power off sequence. In the power off sequence, the MPU 171 first changes the level of the output signal 1 g of the output port 19 to “L” level, whereby the transistor 20 comes to be in the off state. Thus, the potential of the signal line 1 h becomes “H” level, the DC-Dc converter 4 stops oscillating, and the logic power source voltage V CC decreases.
Then, if the logic power source voltage V CC becomes a certain level or less, the output of the reset circuit 21 , i.e., the signal 1 j , becomes “L” level. As a result, it is possible to prevent an erroneous operation of the transistor 20 due to that the output signal of the output port 19 becomes unstable.
Hereinafter, a control procedure to be performed by the MPU 171 when the power source of the printer 1 is turned on/off will be explained with reference to the flow chart shown in FIG. 6 .
As described above, in the present embodiment, it is assumed that the power switch 17 is depressed by the user to operate the printer 1 , the logic voltage V CC is resultingly supplied to the logic circuit including the MPU 171 of the printer, the power source voltage is supplied to the printer 1 , and the reset is released after elapsing the regulated period of time T after the voltage is applied to the logic circuit including the MPU 171 . Thus, the MPU 171 starts the control according to the program stored in the ROM 172 .
After the reset is released, in a step S 101 , the signal of “H” level is first output to the output port 19 to turn on the transistor 20 , whereby the oscillation state of the DC-DC converter 4 is maintained, and the power is continuously supplied from the AC adapter 2 .
Next, in a step S 102 , the output signal 1 f to the input port 18 is read to check whether or not the power switch 17 of the printer 1 is depressed. If the power switch 17 is not depressed, it is considered that the AC adapter 2 is only connected to the printer 1 but the user does not wish to start the printer, whereby the step advances to a step S 106 .
Then, it is checked in the step S 106 whether or not the secondary battery is connected. It should be noted that this check can be performed by measuring the terminal voltage of the connection unit to the secondary battery. Then, it is checked in a step S 107 whether it is necessary to charge the secondary battery. If it is considered in the step S 106 that the secondary battery is not mounted or if it is checked in the step S 107 that it is unnecessary to charge the secondary battery even if it is mounted, the flow advances to a step S 110 .
On the other hand, if it is considered that the secondary battery is mounted and it is necessary to charge the secondary battery, the flow advances to a step S 108 to perform the charging until the battery comes to be in the full-charged state, as checking in a step S 109 whether the battery comes to be in the full-charged state.
In the step S 110 , the signal of “L” level is output to the output port 19 to turn off the transistor 20 , whereby the DC-DC converter 4 stops oscillating. As a result, the voltage V CC becomes 0V, and the MPU 171 stops operating.
On the other hand, if it is considered in the step S 102 that the power switch 17 is depressed, the printer is operated in a step S 103 . Here, the printer first performs an initialization operation when the power source is turned on. For example, the printer performs a recovery operation of the recording head to set the state that the recording head can satisfactorily discharge inks. Moreover, as the initialization operation, the printer starts communication with the host apparatus such as the personal computer or the like. Then, the printer receives and records the data sent from the personal computer, and performs the recovery operation of the recording head between the recording operations according to need.
While the printer is operating, the state of the power switch 17 is always checked by polling or interrupt in a step S 104 . If it is considered in the step S 104 that the power switch 17 is depressed during the operation of the printer, the flow advances to a step S 105 to end the currently performed operation of the printer, and the flow further advances to the step S 110 to interrupt the power supply from the AC adapter 2 .
As explained above, when the AC adapter is connected to the outlet of the AC power source, the DC-DC converter 4 is turned on for a certain period of time to supply the power to the printer even if the power switch is not turned on, whereby the MPU can operate. Thus, it is possible to check the state of the secondary battery and to charge the secondary battery if necessary. If the charging is unnecessary or completed, the MPU stops operating, the DC-DC converter 4 is turned off, and the printer is on standby until the power switch is turned on, whereby the power consumption of the printer system becomes zero.
<Second Embodiment>
FIG. 7 is a block diagram showing the detailed structure of a power supply unit of a printer 1 . The structure in the present embodiment differs from the structure of FIG. 3 explained in the first embodiment in the point that there is no secondary battery and no charging circuit for the secondary battery, that is, other portions in the present embodiment are the same as those in the first embodiment.
Therefore, since the sequence to turn on/off the power source in the present embodiment is the same as that in the first embodiment, the explanation of main signals will be omitted.
Then, a control procedure to be executed by an MPU 171 when the power source of the printer 1 is turned on/off will be explained with reference to a flow chart shown in FIG. 8 .
After the reset is released, in a step S 201 , a signal of “H” level is first output to an output port 19 to turn on a transistor 20 , whereby the oscillation state of a DC-DC converter 4 is maintained, and the power is continuously supplied from an AC adapter 2 .
Next, in a step S 202 , an output signal 1 f to an input port 18 is read to check whether or not a power switch 17 of the printer 1 is depressed. If the power switch 17 is not depressed, it is considered that the AC adapter 2 is only connected to the printer 1 but a user does not wish to start the printer, whereby the step advances to a step S 206 .
Then, it is checked in the step S 206 whether or not a carriage is capped. It should be noted that this check is performed by a position sensor (not shown) on the carriage. Then, if the carriage is capped, the flow advances to a step S 208 , while if the carriage is not capped, a capping operation to move the carriage to a capping position is performed in a step S 207 . The capping is not only to protect the surface of the recording head but also to be able to prevent the ink from flowing out of a not-shown ink tank (including a waste ink tank) of the portable printer, whereby it is very effective.
Incidentally, when the capping operation is performed, recovery operations such as a preliminary discharging operation, a wiping operation and the like to protect the surface of the recording head are performed according to need.
In the step S 208 , the signal of “L” level is output to the output port 19 to turn off the transistor 20 , whereby the DC-DC converter 4 stops oscillating. As a result, a voltage V CC becomes 0V, and the MPU 171 stops operating.
On the other hand, if it is considered in the step S 202 that the power switch 17 is depressed, the printer is operated in a step S 203 . Here, the printer first performs an initialization operation when the power source is turned on. For example, the printer performs a recovery operation of the recording head to set the state that the recording head can satisfactorily discharge inks. Moreover, as the initialization operation, the printer starts communication with the host apparatus such as a personal computer or the like. Then, the printer receives and records the data sent from the personal computer, and performs the recovery operation of the recording head between the recording operations according to need.
While the printer is operating, the state of the power switch 17 is always checked by polling or interrupt in a step S 204 . If it is considered in the step S 204 that the power switch 17 is depressed during the operation of the printer, the flow advances to a step S 205 to end the currently performed operation of the printer, and the flow further advances to the step S 208 to interrupt the power supply from the AC adapter 2 .
As explained above, when the AC adapter is connected to the outlet of the AC power source, the DC-DC converter 4 is turned on for a certain period of time to supply the power to the printer, whereby the MPU can operate. Thus, it is checked whether or not the recording head is capped, and the capping operation is performed if necessary. If the capping operation is unnecessary, the MPU stops operating, and the DC-DC converter 4 is turned off, whereby the power consumption of the printer system becomes zero. As above, in the first and second embodiments, although the integration circuit composed by the resistor R 1 and the capacitor C 1 is described as the example of the way to turn on the step-down circuit for the certain period of time when the AC adapter is connected and when the printer is connected to the AC outlet, it is possible to achieve the same function by using a differentiating circuit.
Moreover, in the embodiments, the tact switch having the structure to be on in the case where the switch is being depressed is explained by way of example of the power switch for operating the printer. However, the present invention is not limited to this, that is, other type of switch such as a slide switch or the like is applicable.
Moreover, in the embodiments, the DC-DC converter is described by way of example of the step-down circuit for generating the logic voltage. However, it is apparent that a voltage regulator (often called a three-terminal regulator, in general) having output control terminals can be used.
Moreover, as the method of judging whether or not it is necessary to charge the secondary battery, the method of performing the judgment based on the value of the charging current is described, but other method is applicable. For example, if there is information concerning the charging to the secondary battery, a method of performing the judgment based on this information is applicable.
Moreover, the regulated period of time T of the reset signal in the reset circuit is 100 msec. However, other value is applicable if it satisfies the control according to the embodiments. Besides, the output value of the AC adapter is 16 V, other voltage value is applicable.
According to the present invention, it is possible to suppress the power consumption of the ink-jet printer to approximately zero when the printer is being turned off, whereby there is an effect of enabling to provide the apparatus that the power consumption of the overall ink-jet printer including the power supply unit is extremely small.
Moreover, even if the power source of the ink-jet printer is in the off state, it is possible, without user's operation, to perform the process only by connecting the AC adapter. | An ink-jet printer includes a control circuit for controlling a recording operation by receiving power supply from an AC adapter, a voltage output circuit for outputting a voltage on the basis of a signal output by the AC adapter, and a voltage output control circuit for turning on and off the voltage output circuit. In the printer, in case of starting the power supply from the AC adapter, the voltage output control circuit sets the output of the voltage output circuit to an off state after setting the output to an on state for a certain period of time, whereby it is possible to decrease reactive power while the electronic apparatus is not powered. | 8 |
BACKGROUND OF THE INVENTION
The present invention is directed to means that readily places the rotor in axial alignment with a rotor support bearing to preclude any mis-alignment during operation that might lead to loosening, fracture and failure of a connecting arrangement therebetween.
More particularly, the present invention relates to a centering device that attains rapid alignment and insures continuous axial alignment between the rotor and a housing of a support bearing therefor. After alignment of the rotor and the housing for a support bearing has been achieved, a support bearing is readily substituted for the centering device to assure a long period of trouble-free operation under conditions that include substantially perfect alignment.
BRIEF DESCRIPTION OF THE DRAWING
A more complete understanding of my invention may be realized by referring to the following description in addition to the accompanying drawings in which:
FIG. 1 is a sectional elevation of a rotary regenerative heat exchanger constructed in accordance with the accompanying invention,
FIG. 2 is an enlarged sectional elevation showing the construction details of a rotor centering device, and
FIG. 3 is an enlarged sectional elevation showing a radial bearing in position replacing the centering device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the apparatus shown in the drawing, a rotor shell 10 is spaced concentrically about a central rotor post 12 to provide an annular space therebetween that houses a mass of heat absorbent material 14. The heat absorbent material is contacted alternately by a stream containing a heating fluid and a stream containing a fluid to be heated that traverse the rotor in opposite directions through housing 26 that surrounds the rotor. While the various fluids are traversing the rotor, the rotor is being slowly and continuously rotated about its axis by suitable drive means (not shown) so that the fluids alternately contact spaced parts of the rotor and thus transfer heat from the heating fluid to the fluid to be heated.
The rotor is mounted for continuous rotation about its own vertical axis on a support bearing 32 at one end of the trunnion 38 and a guide bearing 40 at the opposite end of the rotor. The support bearing 32 rests on an annular shoulder 43 that is contained in housing 34 held by bolts 37 to the underside of support beam 36 that extends under the rotor. The annular shoulder 43 includes a central cavity 64 for a radial bearing 41 that is secured to the end of the trunnion to prevent lateral movement thereof, while a removable door 39 permits access to cavity 64.
In the past it has been customary to position the rotor within its surrounding housing and support bearing by simply lowering the rotor and its connecting trunnion into suitable housing structure and then centering it visually in the best manner possible. The rotor was repeatedly raised and lowered, pushed and pulled and then connected to a support bearing when it appeared to be in axial alignment. Any misalignment between the trunnion and the support bearing would result in excessive spacing between adjacent parts, uneven wear, eventual fracture of any coupling means, and finally complete rotor stoppage.
A continuous process of upkeep and repair consequently was required to maintain the rotor properly supported for rotation upon a suitable support bearing. Frequently, even what appeared to be satisfactory was actually imperfect alignment that would require continued re-positioning, re-aligning and re-tightening of any connecting means between the bearing and the support trunnion.
In accordance with this invention the rotor support trunnion 38 is adapted to extend axially down from the rotor post 12 into concentrically spaced relation with support bearing housing 34. The annular surface 43 in housing 34 is adapted to support the thrust bearing 32 on the upper surface thereof and the radial bearing 41 in the inner cavity 64 to preclude lateral movement of trunnion 38. The cavity 64 also serves to receive a temporary centering device that aligns the rotor concentrically within the surrounding rotor housing.
The centering device comprises essentially a central stem 54 having an axial bore 56 extending therethrough to receive a bolt 52 in threaded recess 48 concentrically centered in the end of trunnion 38. The bolt 52 may be manipulated through open door 39 at the bottom of the housing. Upon turning the bolt 52, the boss 44 may be drawn tightly into the threaded recess at the bottom of trunnion 38 to provide complete axial alignment between the trunnion 38 and the stem 54.
The stem 54 is provided with a transverse disc 62 formed integrally therewith and having an extreme outside diameter that is only slightly less than that of cavity 64 thus permitting freedom of rotation therein. The lateral edges of disc 62 are chamfered severly to provide a point contact in the manner shown by FIG. 2 that permits the entire centering device 54 to be tilted within the cylindrical cavity 64 until the bolt 52 may engage the threads of threaded recess 48 and by tightening, may be drawn thereto. After the bolt 52 is tightened and shoulder or boss 44 is drawn into the counterbore, which is aligned with recess 48, the rotor post becomes concentrically aligned with the bearing housing, and it becomes a simple expedient to substitute a radial bearing 41 for the temporary centering device 54.
In assembly, the rotor 10 is simply lowered into its housing 26 in what appears to be an axially aligned relation thereto. The temporary centering device is then inserted in cavity 64 and tilted around until the bolt 52 contacts the threaded recess 48. Upon turning the bolt 52, the boss 44 will be drawn into the counterbore of the trunnion 38, and the centering device 54 will be brought into perfect axial alignment therewith. When axially aligned, the centering device 54 may be removed by removal of bolt 52, an axial thrust bearing 32 centered on surface 43, and the radial bearing 41 may be substituted for the centering device 54.
Various arrangements such as including shims under spaced parts of the rotor may be used to hold the rotor in a fixed position in the rotor housing after a concentric arrangement has been obtained. Inasmuch as numerous arrangements having a similar result may be used, such arrangements are not made a part of this invention. It should be evident therefore that various changes may be made in the specific design shown or the particular sequence of operation without departing from the spirit of the invention. Therefore, all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense. | A device used when assembling rotary regenerative heat exchange apparatus having a rotor disposed about a vertical rotor shaft by which the rotor thereof may be quickly aligned vertically over a subjacent support bearing to preclude mis-alignment during operation. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/985,643 filed on Apr. 29, 2014, which is incorporated herein by reference.
STATEMENT OF GOVERNMENT RIGHTS
The inventions described herein may be manufactured, used and licensed by or for the U.S. Government for U.S. Government.
BACKGROUND
1. Field of the Invention
The present invention relates to a weapon suppressor system capable of minimizing the gas backflow to the operator and to the weapon's operating system, as well as, minimizing the weapon flash—the system comprising a unique central baffle and bypass system.
2. Description of the Related Art
Firearm suppressors are designed to attach to the muzzle of a weapon and reduce the noise and flash generated by said weapon when it is fired. While there are numerous suppressor designs which may accomplish this, an issue which remains is how to accomplish this while not affecting the overall performance of the weapon, especially high rate of fire weapons such as machine guns and carbines. Typical baffle sections in most suppressors do not allow for rapid blowdown of the weapon due to supersonic flow choking effects at each baffle section. As a result the flow chokes and slows blowdown of the weapon at each section. As a result, pressure and temperature gradients form in the suppressor. This often cause slow blowdown, high pressure at the breech during weapon cycling, high pressure sections in the suppressor, which may require significant wall thickness and added weight, and higher temperatures in the high pressure sections.
Proper management of weapon blowdown is critical for several reasons. Weapon blowdown is the rate at which the weapon barrel empties the propellant gases after the projectile leaves the weapon. Suppressors, when added to a weapon typically reduce the blow down rate and increase the back pressure in the weapon. In addition they can cause an “organ pipe effect” whereby pressure waves to ring back and forth in the barrel/suppressor system.
A primary effect of the reduced blowdown is an increases in pressure at the breech during case ejection of automatic or semi-automatic weapons. Case extraction can occur within milliseconds of firing and breech pressures with a suppressor installed can be 2 to 3 orders of magnitude higher if blowdown is not properly managed. This high pressure can cause case ejection problems, propellant fouling, propellant gases in the operators face and other problems. In addition, a reduced blowdown rate can cause changes in weapon powering of either piston driven or gas tube driven weapons. The decreased blowdown rate causes the pressure at the barrel gas port to be higher for a longer period of time and hence provides more power to the gas piston or gas operating mechanism. This can cause increased bolt velocities beyond weapon design limits and potentially damage weapon parts unless pressures can be reduced at the gas port by some means.
In order to increase the blowdown rates of a weapon with a suppressor it is critical to provide good blast overpressure reduction while at the same time emptying the suppressor can as fast as possible. The critical issue with regards to blowdown management of weapon suppressors is to increase the blowdown rate while not increasing the blast overpressure levels significantly.
Low visual signature is often important as well, to reduce the ability of an enemy to visually locate a firing position. Weapon flash may be caused by unburnt propellant at high temperatures exiting the suppressor where it mixes with the outside air and ignites. Reducing this flash is desirable.
Thermal management of weapon suppressors is also critical because they tend to absorb large amounts of heat when placed on a weapon. Suppressors have much larger internal surface areas than weapon barrels and as a result can absorb more heat from the propellant gases. While some suppressors may reduce the pressure of the exiting flow by acting as a heat sink to absorb thermal energy, thereby cooling the gas and reducing its volume, this effect would rapidly diminish with each shot of an automatic weapon, where the suppressor would heat up and no longer be able to cool the gas to reduce pressure.
Thus there is a need for a suppressor which can rapidly blowdown the contained pressure when used with a rapid firing weapon, while providing good sound suppression and minimizing visual signature and effectively managing thermal energy. This is accomplished through a combination of various design features described below.
A comparison to prior art U.S. Pat. No. 8,286,750 B1—‘Energy Capture and Control Device’, hereafter referred to as '750, is made here.
'750 is an “energy capture and control” device. Because of the large surface area and extensive turning through the use of multiple tubes, multiple internal wall, a serpentine flow path as a method to lengthen the flow path, it is expected that this will produce a device that “dissipates energy transferred from the high energy material” to the suppressor structure. Hence the suppressor becomes a heat sink for the high temperature propellant gases. This is accomplished by both increasing the turbulence of the flow by providing multiple and aggressive turning as well as providing large surface area or large contact area with the gas to increase heat transfer to the suppressor. It has been shown that pulling heat from the gases reduces the pressure of the gases and reduces the blast overpressure. This shows that one of the primary ways this suppressor functions is through temperature reduction of the gases. The '750 design is well suited to low rate of fire weapons such as sniper rifles and potentially some carbines. Otherwise the suppressor will soon reach peak temperature and no longer provide sufficient sound reduction since the suppressor is too hot to capture energy and reduce sound. Hence it should be noted that the '750 sound suppression technique utilized is primarily temperature reduction of the gas which in turn provides a pressure reduction. It is not primarily a pressure reduction device.
The off axis flow in '750 uses a serpentine flow path. The multiple internal walls actually decrease the volume of the fluid expansion, not increase it. The volume of the wall material reduces the available expansion volume and hence reduces the pressure reduction of the suppressor which would be due to volume increase. While the internal walls of '750 do increase the flow path length by using a “radially serpentine” flow path which cases the flow to go back and forth in addition to going around the central chamber due to the helical internal wall structure, creating gas turning, increased turbulence, and high amounts of wall heat transfer, the high heat transfer rate to the wall of the prior art will only work as long as the suppressor heats up to an a reasonable operating temperature after a limited number of shots. As a result, the '750 design losses effectiveness as it heats up since it gets its suppression primarily through temperature reduction.
Further by adding four to five inner tubes to the inside of the suppressor, the additional internal surface area is significantly higher. Heat transfer is typically proportional to surface area until the gas cools sufficiently that heat transfer to the wall no longer happens. As a result, the prior art suppressor will have more total heat transferred to the suppressor per shot. In a machine gun situation, the heating rate will be higher and the final temperature after a given number of rounds should be higher.
The inner tube system also drastically reduces the effective cross-sectional area significantly. As a result, the effective cross-sectional area is likely less than the exit area of the suppressor. As a result, flow could choke at any given point along the very long flow path. This could increase blow down time. Short blowdown time is critical for machine gun suppressors. The choked flow would lead to increased back pressure and blowback in a rapid fire situation, which could blow back towards the operator and could stress and potentially damage or disrupt the operating system.
K-baffles are utilized in suppressors as discussed in the background of U.S. Pat. No. 7,987,944 ‘Firearm sound suppressor baffle’: One typical conventional baffle is referred to as a “K-baffle,” . . . . The K-baffle is generally defined by a rear plate portion that is generally flat and oriented transverse to the axial bore of the suppressor and a forward bell portion extending in a forward direction from the rear plate portion along the longitudinal axis of the K-baffle. The rear plate portion includes a central aperture for a projectile to pass through the K-baffle in the forward direction. The forward bell portion increases in annular cross-section from the central aperture and rear plate portion to a forward end, which is configured to about a rear plate portion of a subsequent K-baffle. Thus, the K-baffle defines an interior chamber within the forward bell portion and an exterior chamber between the rear plate portion and the forward bell portion outside of the forward bell portion. The interior chamber and exterior chamber is typically fluidly connected by a flow aperture cut into the forward bell portion. Consequently, a plurality of K-baffles defines a plurality of blast chambers for the burning gases to expand into during firing of the firearm, thereby reducing the noise output of a muzzle blast.
However, as the '944 patent indicates, in a K-baffle ‘The interior chamber and exterior chamber is typically fluidly connected by a flow aperture cut into the forward bell portion.’, such as is not the case in the subject invention. In a typical K-baffle system the flow apertures lead into side chambers which dead-end. In a rapid fire environment, this dead end would saturate with pressure and not blow down properly, leading to increased blowback, which can blow back towards the operator and could stress and potentially damage or disrupt the operating system.
SUMMARY OF THE INVENTION
A suppressor for automatic and semi-automatic weapons for rapid bleed down of weapon pressure is disclosed which may include: a baffled central chamber, configured along the bore axis, formed by a series unported K-baffles; a baffled bypass chamber, disposed surrounding the central chamber, providing a high flow area, forward directed flow path, wherein inner surface of said bypass chamber is substantially defined by the exterior shape of the unported K-baffles and which may further include a plurality of baffles such as annular rings or ported partitions. Propellant gasses may expand into the bypass chamber before the central chamber begins, and thereafter there is no fluid communication between the central and bypass chambers. The distal end of the suppressor may include a surface which includes a central chamber outlet disposed along the bore axis, and a series of perforations, surrounding the central chamber outlet, which provide outlets for the bypass chamber. The minimum flow area of the bypass chamber exceeds that of the outlet perforations such that, once the suppressor has reached steady state, the bypass flow should choke at the outlets, rather than in the bypass chamber.
The suppressor may be secured to a distal end of a barrel of a weapon and may be formed to have a body portion, or ‘can’, having a bore extending concentric with a bore axis of the barrel when the suppressor is attached to the distal end of the barrel. The suppressor includes a central chamber, configured along the bore axis, which utilizes a multiple chamber unported K-baffle system to reduce the primary blast wave strength. A K-baffle system is typically a plurality of frustoconical segments arranged in series and connected by annular rings creating a baffle chamber. The K-baffle of the subject invention is ‘unported’ in that it does not have typical apertures which would allow fluid communication between the interior and exterior.
This K-baffle system temporarily chokes the flow in each section, and thereby reduces the primary blast wave strength by approximately 52% at each nozzle. Over a half dozen nozzles, this can theoretically reduce the pressure to 2% of its original pressure.
A baffled bypass chamber may be located around the central chamber, where the inner surface of said bypass chamber is substantially defined by the exterior shape of the unported K-baffle and which may further include a plurality of baffles disposed substantially perpendicular to the bore axis, and which may take the form of annular rings or ported partitions, and where the fluid path defined by the baffled bypass chamber proceed substantially forward.
Within the proximal end of the can interior there may be a primary chamber, which provides for fluid communication between the inlet and both the central chamber and the bypass chamber, which allows a portion of the expanding propellant gasses to flow into the bypass chamber. After the central core chamber begins, it is no longer in fluid communication with the bypass chamber and the fluid paths proceed separately within the suppressor.
The distal end of the suppressor may include a surface, which may be a cap attached to the distal end of the can, which includes a core chamber outlet disposed along the bore axis, and a series of perforations, surrounding the core chamber outlet, which provide outlets for the bypass chamber.
The bypass flow moves essentially forward, with no reversals, and the amount of undulation of the flow is reduced to only the amount required to time the exit and control the pressure of the blast waves. Because of the shorter flow path of the by-pass flow, it exits at nearly the same time or before the core or central flow exits. This is not the case in the prior art technology where it is significantly delayed with the serpentine flow path. The timing of this flow is critical.
Because the bypass flow exits at the same time or before the central flow, the bypass flow of the subject invention is able to shield the central core flow as it exits. If the perforations which serve as the bypass chamber exits are positioned close to the exit nozzle of the core, the flow from the end cap may provide a shear layer interaction between the core flow and by-pass flow. The by-pass flow then shields the core flow from oxygen in the surrounding atmosphere and reduces flash by extinguishing flash started in the suppressor core by starving it of oxygen for first round flash. Reducing first round flash is critical for suppression technology as this is often as much of a locater as sound.
Compressible flow theory shows that only one choke point can exist in a given system during steady state flow. Granted a suppressor is not a steady state flow device, it soon reaches near steady-state conditions with 1-2 milliseconds after bullet exit and during the majority of the barrel blow down. Hence one needs to design the entire flow path and carefully control the areas to fix the choke point.
The bypass of an embodiment of the subject invention should be designed such that the choke point occurs at the exit holes. In order to achieve this, all of the upstream areas need to be greater than this final area. In order to ensure this is the case, a general rule that the minimum upstream cross-sectional area be a minimum of 2 to 3 times the exit area, to ensure that the flow is subsonic (Mach 0.3 to 0.5) in order to account for any flow inefficiencies or turning that could cause an effective decrease in flow area. This bypass system allow for rapid bleed down of the final pressure remaining in the weapon.
An added benefit of the bypass flow choke point occurring at the exit holes, is that the flow can be adjusted and optimized to trade-off suppression vs weapon blowback by changing the total exit area, which is the sum of the bypass exit area and the center channel exit area. By reducing the exit area for the optimized suppressor, lower sound can be achieved at the expense of higher blowback and higher weapon overpowering. This allows more control over optimization of the suppressor. The total exit area may be expressed as by the ratio of total exit area of the suppressor to weapon bore area. A total exit area to bore area ratio in the range of 1.5 to 5 is optimum. The exit area can be divided between the core throat area and the by-pass exit area.
Thermal management of weapon suppressors is also critical because they tend to absorb large amounts of heat when placed on a weapon. Suppressors have much larger internal surface areas than weapon barrels and as a result can absorb more heat from the propellant gases. While some suppressors may reduce the pressure of the exiting flow by acting as a heat sink to absorb thermal energy, thereby cooling the gas and reducing its volume,
Thermal management is addressed by subject invention by maintaining a low internal surface area to reduce heat transfer from the gas to the suppressor, and controls the sound through reduction and control of the pressure, not by reducing the temperature of the gas flow, as may be found in the prior art. The subject invention achieves this, in part, by its use of a more direct bypass gas flow path than is seen in the prior art, which eliminates reversals and has minimal undulations along its forward pathing. Non-reliance on heat sink effect for suppression is critical to an automatic weapon suppressor, as the usefulness of a heat sink effect would rapidly diminish with each shot of an automatic weapon, where the suppressor would heat up and no longer be able to cool the gas to reduce pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a . is a cross-sectional side view of a device having an unported K-baffle system forming a central chamber, surrounded by a baffled bypass chamber with ported partition baffles in accordance with an example of the subject invention.
FIG. 1 b . is a perspective view of the ported partition baffles of the bypass chamber and the K-baffle system may be fabricated as a single component in accordance with an example of the subject invention.
FIG. 1 c . is an end on view of a the distal end of the embodiment of the suppressor of FIG. 1 a , showing the cap which may be attached to the distal end of the can, which includes a central chamber outlet and a series of perforations of a kidney bean shape in accordance with an example of the subject invention.
FIG. 2 . is a cross sectional perspective view of an alternate embodiment may have a series of separately fabricated sections, each section substantially comprised of a chamber of the unported K-baffle system and the adjacent bypass baffle, arranged in series within the can, forming the uninterrupted central flow path of the unported K-baffle system.
FIG. 3 . is a cross sectional perspective view of yet another embodiment, wherein substantially the entire structure, which includes the unported K-baffle system, the bypass baffles, the can, proximal end inlet, and longitudinal ribs are cast as one component. The distal end surface containing the central outlet and bypass perforations is depicted as a separately fabricated endcap.
FIG. 4 a . is a perspective view of the another embodiment of the invention, where substantially all of the interior components, including the unported K-baffle system, annular ring bypass baffles proximal surface, distal surface and longitudinal ribs having been fabricated as a single piece.
FIG. 4 b . is a cross sectional perspective view of the embodiment of FIG. 4 a ., with the single piece fabrication of the interior components contained within the can.
DETAILED DESCRIPTION
Note that the terms ‘central chamber’, ‘core chamber’ and ‘central core chamber’ are used interchangeably.
As shown in FIG. 1 a , suppressor [ 100 ] for automatic and semi-automatic weapons for rapid bleed down of weapon pressure, according to an embodiment of the subject invention, may include: a baffled central chamber [ 101 ], configured along the bore axis, formed by a series unported K-baffles [ 102 ]; a baffled bypass chamber [ 103 ], disposed surrounding the central chamber [ 101 ], providing a high flow area, forward directed flow path, wherein inner surface [ 104 ] of said bypass chamber [ 103 ] is substantially defined by the exterior shape of the unported K-baffle system [ 102 ] and which may further include a plurality of baffles [ 105 , 113 ] such as annular rings or ported [ 117 ] partitions [ 105 ]. Propellant gasses may expand into the bypass chamber [ 103 ] before the central chamber [ 101 ] begins, and thereafter there is no fluid communication between the central [ 101 ] and bypass chambers [ 103 ]. The distal end of the suppressor [ 100 ] may include a surface, which may be disposed on a cap [ 106 ] attached to the distal end of the suppressor [ 101 ] which includes a central chamber outlet [ 107 ] disposed along the bore axis, and a series of perforations [ 108 ], surrounding the central chamber outlet [ 107 ], which provide outlets for the bypass chamber. The minimum flow area of the bypass chamber [ 103 ] exceeds that of the outlet perforations [ 108 ] such that, once the suppressor [ 100 ] has reached steady state, the bypass flow should choke at the outlet perforations [ 108 ], rather than in the bypass chamber [ 103 ].
The suppressor may be secured to a distal end of a barrel of a weapon and may be formed to have a body portion [ 109 ], or ‘can’, having a bore extending concentric with a bore axis of the barrel when the suppressor is attached to the distal end of the barrel. The suppressor includes a central chamber [ 101 ], configured along the bore axis, which utilizes a multiple chamber unported K-baffle system [ 102 ] to reduce the primary blast wave strength.
A K-baffle system [ 102 ] is in the shape of a series of frustoconical sections [ 110 ], axially aligned with the bore axis, identically oriented, with their large diameter at the distal end with respect to the inlet [ 111 ], and with the small diameter end of a subsequent frustoconical section joined to the large diameter end of a preceding section via annular rings [ 112 ], leaving a baffled central channel along the central axis.
While a typical K-baffle has ports or apertures along its body allowing fluid communication between the interior and the exterior, in the subject design, the unported K-baffle system [ 102 ] does not have such ports or apertures and there is no fluid communication between the interior and the exterior of the K-baffle system along its length. This unported K-baffle system [ 102 ] temporarily chokes the flow in each section, and thereby reduces the primary blast wave strength by approximately 52% at each nozzle. Over a half dozen nozzles, this can theoretically reduce the pressure to 2% of its original pressure.
The bore of the unported K-baffle system [ 102 ] should may have a minimum diameter which is greater than the bore of the weapon, and thus greater than the diameter of the bullets traveling there though, in part to minimize the chance of the said bullet striking the interior of the suppressor. The exterior of the K-baffle system is of a smaller maximum diameter than the inner surface of the can.
A baffled bypass chamber [ 103 ] may be located around the central core, where the inner surface [ 104 ] of said bypass chamber is substantially defined by the exterior shape of the unported K-baffle system [ 102 ] and which may further include a plurality of baffles [ 105 , 113 ] disposed substantially perpendicular to the bore axis, and which may take the form of annular rings [ 113 ] or ported partitions [ 105 ], and where the fluid path defined by the baffled bypass chamber proceed substantially forward. These baffles may be coplanar with the annular rings of the unported K-baffle system [ 102 ], as shown in the embodiment of FIGS. 1 a and 1 b , or their planes may longitudinally located at the frustoconical sections. In one embodiment, the unported partition baffles of the bypass chamber and the K-baffle system may be fabricated as a single component [ 116 ] as shown in FIG. 1 b , which may be contained within the can [ 109 ], as depicted in FIG. 1 a.
An alternate embodiment [ 200 ] as shown in FIG. 2 , may have a series of separately fabricated sections [ 201 ], which may be machined parts, where each section substantially comprises a chamber of the unported K-baffle system, perhaps together with an adjacent bypass baffle, and whereby a series of these fabricated sections are arranged in series within the can, and seat and seal with the adjacent sections, forming the uninterrupted central flow path of the unported K-baffle system.
In yet another embodiment [ 300 ], as shown in FIG. 3 , substantially the entire structure, which may include the unported K-baffle system, the bypass baffles, the can, and proximal end inlet, may be cast as one component, using, for instance, an investment casting process, such as lost wax casting. While the distal end surface containing the central outlet and bypass perforations may be included in the single casting, or may be fabricated separately, and attached.
In yet another embodiment [ 400 , 401 ], as shown in FIG. 4 a and FIG. 4 b . substantially all of the interior components, including the unported K-baffle system, annular ring bypass baffles [ 113 ], proximal surface, distal surface and longitudinal ribs [ 301 ] having been fabricated as a single piece [ 400 ], depicted in FIG. 4 a . This single piece fabrication of the interior components is then contained in the can [ 109 ], as depicted in FIG. 4 b.
There may be a distance within the can between the suppressor inlet [ 111 ] at the distal end of the barrel and the proximal end of the central core chamber [ 101 ], said space provided by said distance may be referred to as the primary chamber [ 114 ], and which space provides for fluid communication between the inlet [ 111 ] and both the central chamber [ 101 ] and the bypass chamber [ 103 ], which allows a portion of the expanding propellant gasses to flow into the bypass chamber [ 103 ]. After the central core chamber [ 101 ] begins, it is no longer in fluid communication with the bypass chamber [ 103 ] and the fluid paths proceed separately within the suppressor.
The unported K-baffle system [ 102 ] may be structurally maintained in position along the center axis by either the baffles of the bypass channel, should they be of a ported partition baffle [ 105 ] type, which may extend from the can inner surface [ 115 ] to the unported K-baffle system [ 102 ], or by longitudinal ribs [ 301 ], which may divide the bypass chamber [ 103 ] and possibly a portion of the primary chamber radially. Longitudinal supports, running substantially parallel to the bypass flow path, will have negligible effect on the flow, and the aggregate flow of the now radially separated bypass chambers may be treated similarly to a single undivided bypass chamber [ 103 ]. The thickness and heat conductivity of such features which may be in communication with both the unported K-baffle system [ 102 ] and the external body ‘can’ [ 109 ], will affect their capacity for thermal conduction from the unported K-baffle system [ 102 ] to the exterior of the body. As such, it may be advantageous to construct these features to be slightly thicker and of a material that conducts the thermal energy (around 20 W/m-K) outward to the exterior to be dissipated, rather than absorbing it. However, there is a tradeoff regarding the thickness of these structures, as wall volume should otherwise be minimized in order to increase the expansion volume to the maximum allowable.
The distal end of the suppressor may include a distal surface, which may be comprised of a cap [ 106 ] attached to the distal end of the can [ 109 ], which includes a central chamber outlet [ 107 ] disposed along the bore axis, and a series of perforations [ 108 ], surrounding the central chamber outlet [ 107 ], which provide outlets for the bypass chamber. These perforations may be circular or may be oblong, substantially of an arc, or kidney bean shape [ 108 ], as shown in FIG. 1 c.
The bypass flow moves essentially forward, with no reversals, and the amount of undulation of the flow is reduced to only the amount required to time the exit and control the pressure of the blast waves. Because of the shorter flow path of the by-pass flow, it exits at nearly the same time as the core or central flow. This is not the case in the prior art technology where it is significantly delayed with the serpentine flow path. The timing of this flow is critical.
Because the bypass flow exits at nearly the same time as the central flow, the bypass flow of the subject invention is able to shield the central core flow as it exits. If the perforations [ 108 ] which serve as the bypass chamber exits are positioned close to the center chamber outlet [ 107 ], the flow from the perforations [ 108 ] may provide a shear layer interaction between the core flow and bypass flow. The bypass flow then shields the core flow from oxygen in the surrounding atmosphere and reduce flash by extinguishing core flow flash and starving it from oxygen. Reducing first round flash is critical for suppression technology as this is often as much of a locater as sound.
The subject invention provides for control of the off axis flow. Because suppressors operate in the “compressible flow regime” aerodynamically, the control of cross-sectional areas perpendicular to the flow path is critical. Compressible flow theory shows that only one choke point can exist in a given system during steady state flow. Granted a suppressor is not a steady state flow device, it soon reaches near steady-state conditions with 1-2 milliseconds after bullet exit and during the majority of the barrel blow down. Hence one needs to design the entire flow path and carefully control the areas to fix the choke point.
The bypass chamber [ 103 ] of an embodiment of the subject invention should be designed such that the choke point occurs at the exit holes. In order to achieve this, all of the upstream areas need to be greater than this final area. In order to ensure this is the case, a general rule that the minimum upstream cross-sectional area be a minimum of 2 to 3 times the exit area, to ensure that the flow is subsonic (Mach 0.3 to 0.5) in order to account for any flow inefficiencies or undulation that could cause an effective decrease in flow area. This bypass system allow for rapid bleed down of the final pressure remaining in the weapon.
The in bypass designs with extreme turning, such as in the prior art, it would be very difficult to oversize the cross-section sufficiently to account for effective reductions in cross-sectional area. Hence, the flow could choke at any place along the flow path but likely well upstream of the exit. What this does is significantly reduce the flow rate through the suppressor and reduce the time to empty the gun barrel of gas. This is critical in machine gun applications where firing rates are close to 12 to 14 bullets per minute.
An added benefit of the bypass flow choke point occurring at the exit holes, is that the flow can be adjusted and optimized to trade-off suppression vs weapon blowback by changing the total exit area, which is the sum of the bypass exit area and the center channel exit area. By reducing the exit area at the optimized suppressor lower sound can be achieved at the expense of higher blowback and higher weapon overpowering. This allows more control over optimization of the suppressor. The total exit area may be expressed as by the ratio of total exit area of the suppressor to weapon bore area. A total exit area to bore area ratio in the range of 1.5 to 5 is optimum. The exit area can be divided between the core throat area and the by-pass exit area.
Thermal management of weapon suppressors is also critical because they tend to absorb large amounts of heat when placed on a weapon. Suppressors have much larger internal surface areas than weapon barrels and as a result can absorb more heat from the propellant gases. While some suppressors may reduce the pressure of the exiting flow by acting as a heat sink to absorb thermal energy, thereby cooling the gas and reducing its volume,
Thermal management is addressed by subject invention by maintaining a low internal surface area to reduce heat transfer from the gas to the suppressor, and controls the sound through reduction and control of the pressure, not by reducing the temperature of the gas flow, as may be found in the prior art. The subject invention achieves this, in part, by its use of a more direct bypass gas flow path than is seen in the prior art, which eliminates reversals and has minimal undulations along its forward pathing. Non-reliance a heat sink effect for suppression is critical to an automatic weapon suppressor, as the usefulness of a heat sink effect would rapidly diminish with each shot of an automatic weapon, where the suppressor would heat up and no longer be able to cool the gas to reduce pressure. | A suppressor for rapid fire weapons designed to rapidly bleed down the weapon pressure and thereby minimizing gas blowback to the operator and to the weapon's gas operating system; while also creating a shear gas flow about the exiting bullet's gas flow to mask the flash thereof. The suppressor is configured within a generally cylindrical housing, having: (1) a central core of unported K-baffles located about a central bulletway; (2) a bypass located between the cylindrical housing and the unported K-baffled central core—providing a generally forward subsonic high gas flow area to an endcap closing the cylindrical housing; (3) said endcap having a series of vent ports for the bypass, which also create a shear flow about the centrally exiting bullet; and (4) wherein the series of unported K-baffles are spaced away from the weapon's bore end to allow the propellant gasses to expand into the bypass. | 5 |
GOVERNMENT RIGHTS
This invention was made with government support under Contract Number DE-AC07-991D13727 and Contract Number DE-AC07-051D14517 awarded by the United States Department of Energy. The government has certain rights in the invention.
STATEMENT ACCORDING TO 37 C.F.R. §1.821(c) or (e)—SEQUENCE LISTING SUBMITTED AS A TXT AND PDF FILES
Pursuant to 37 C.F.R. §1.821(c) or (e), files containing a TXT version and a PDF version of the Sequence Listing have been submitted concomitant with this application, the contents of which are hereby incorporated by reference.
BACKGROUND
Dilute acid hydrolysis to remove hemicellulose from lignocellulosic materials is one of the most developed pretreatment techniques for lignocellulose and is currently favored (Hamelinck et al., 2005) because it results in fairly high yields of xylose (75% to 90%). Conditions that are typically used range from 0.1 to 1.5% sulfuric acid and temperatures above 160° C. The high temperatures used result in significant levels of thermal decomposition products that inhibit subsequent microbial fermentations (Lavarack et al., 2002). High temperature hydrolysis requires pressurized systems, steam generation, and corrosion resistant materials in reactor construction due to the more corrosive nature of acid at elevated temperatures.
Lower temperature acid hydrolyses are of interest because they have the potential to overcome several of the above shortcomings (Tsao et al., 1987). It has been demonstrated that 90% of hemicellulose can be solubilized as oligomers in a few hours of acid treatment in the temperature range of 80° C. to 100° C. It has also been demonstrated that the sugars produced in low temperature acid hydrolysis are stable under those same conditions for at least 24 hours with no detectable degradation to furfural decomposition products. Finally, sulfuric acid typically used in pretreatments is not as corrosive at lower temperatures. The use of lower temperature acid pretreatments requires much longer reaction times to achieve acceptable levels of hydrolysis. Although 90% hemicellulose solubilization has been shown (Tsao, 1987), the bulk of the sugars are in the form of oligomers and are not in the monomeric form. The organisms currently favored in subsequent fermentation steps cannot utilize sugar oligomers (Garrote et al., 2001) and the oligomer-containing hydrolysates require further processing to monomers, usually as a second acid or alkaline hydrolysis step (Garrote et al., 2001).
Other acidic pretreatment methods include autohydrolysis and hot water washing. In autohydrolysis, biomass is treated with steam at high temperatures (˜240° C.), which cleaves acetyl side chains associated with hemicellulose to produce acetic acid that functions in a similar manner to sulfuric acid in acid hydrolysis. Higher pretreatment temperatures are required as compared to dilute sulfuric acid hydrolysis because acetic acid is a much weaker acid than sulfuric. At temperatures below 240° C., the hemicellulose is not completely hydrolyzed to sugar monomers and has high levels of oligomers (Garrote et al., 2001). In hot water washing, biomass is contacted with water (under pressure) at elevated temperatures 160° C. to 220° C. This process can effectively hydrolyze greater than 90% of the hemicellulose present, and the solubilized hemicellulose was typically over 95% in the form of oligomers (Liu and Wyman, 2003).
BRIEF SUMMARY
Embodiments relate to a nucleotide sequence of the genome of Alicyclobacillus acidocaldarius , or a homologue or fragment thereof, in combination with at least one sequence that is heterologous to Alicyclobacillus acidocaldarius . In one embodiment, the nucleotide sequence is SEQ ID No. 1 or a homologue or fragment thereof. In another embodiment, the nucleotide sequence has at least 90% sequence identity to SEQ ID No. 1.
Embodiments may further relate to an isolated and/or purified nucleic acid sequence comprising a nucleic acid sequence encoding a polypeptide selected from the group consisting of a polypeptide having at least 90% sequence identity to SEQ ID No. 2, the nucleic acid sequence in combination with at least one sequence that is heterologous to Alicyclobacillus acidocaldarius.
Embodiments also relate to the use of isolated and/or purified polypeptides encoded by a nucleotide sequence of the genome of Alicyclobacillus acidocaldarius , or a homologue or fragment thereof. In one embodiment, the polypeptide is SEQ ID No. 2 or a homologue or fragment thereof. In another embodiment, the polypeptide has at least 90% sequence identity to SEQ ID No. 2. In these and other embodiments, the polypeptide has activity as an acetyxylan esterase.
In embodiments, the polypeptides may be acidophilic and/or thermophilic. In further embodiments, the polypeptides may be glycosylated, pegylated, and/or otherwise post-translationally modified.
Embodiments include methods of at least partially degrading, cleaving, or removing polysaccharides, lignocellulose, cellulose, hemicellulose, lignin, starch, chitin, polyhydroxybutyrate, heteroxylans, glycosides, xylan-, glucan-, galactan-, and/or mannan-decorating groups. Such methods may comprise placing a polypeptide having at least 90% sequence identity to SEQ ID No. 2 in fluid contact with a polysaccharide, lignocellulose, cellulose, hemicellulose, lignin, starch, chitin, polyhydroxybutyrate, heteroxylan, glycoside, xylan-, glucan-, galactan-, and/or mannan-decorating group.
These and other aspects of the disclosure will become apparent to the skilled artisan in view of the teachings contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a sequence alignment between SEQ ID NO:2 (RAAC02760), an acetylxylan esterase, and gi|944285589, gi|916736932, gi|917405684, gi|954102927, and gi|955294285 (SEQ ID NOs:3-7 respectively) which are all esterases. Amino acids common to all of the sequences are indicated by a “*”, while amino acids with only conservative substitutions are indicated by “:”.
FIG. 2 depicts a representation of the activity of four different preparations (represented as Xs, triangles, squares, and diamonds) of SEQ ID NO: 2. Therein, the activity (units/mg) as an acetylxylan esterase is shown at 10, 15, and 20 minutes.
DETAILED DESCRIPTION
Lignocellulose is a highly heterogeneous three-dimensional matrix comprised of cellulose, hemicellulose, and lignin. Many fuels and chemicals can be made from these lignocellulosic materials. To utilize lignocellulosic biomass for production of fuels and chemicals via fermentative processes, it is necessary to convert the plant polysaccharides to simpler sugars, which are then fermented to products using a variety of organisms. Direct hydrolysis of cellulose by mineral acids to monomers is possible at high temperature and pressure, leading to yield losses due to thermal decomposition of the sugars. One strategy to reduce these yield losses is to use cellulases and potentially other enzymes to depolymerize the polysaccharides at moderate temperatures. Addition of acid-stable thermotolerant hydrolytic enzymes such as cellulases and xylanases to the biomass slurry during the pretreatment enables the use of lower temperatures and pressures, as well as cheaper materials of reactor construction, reducing both the capital and energy costs. Another approach is to combine the reduced severity pretreatment with enzymes together with fermentation under the same conditions, using a single organism that produces the enzymes to degrade the material as well as ferment the sugars to the value-added product of choice.
For commercially available enzymes to be used for this purpose, the pretreatment slurry must be neutralized and cooled to 40° C. to 50° C., adding significant cost to the process. Hence, it would be an improvement in the art to degrade the soluble oligomers produced using acid, autohydrolysis or hot water washing pretreatments, at reduced severity and without neutralization using, for example, thermophilic and/or acidophilic enzymes.
Embodiments of the disclosure relate in part to the gene sequences and protein sequences encoded by genes of Alicyclobacillus acidocaldarius . Of particular interest for polysaccharide depolymerization are esterases including acetylxylan esterases. In embodiments, the acetylxylan esterases may be thermophilic and/or acidophilic.
The present disclosure relates to isolated and/or purified nucleotide sequences of the genome of Alicyclobacillus acidocaldarius including SEQ ID No. 1 or fragments thereof. In embodiments, these sequences may be in combination with at least one sequence that is heterologous to Alicyclobacillus acidocaldarius.
The present disclosure likewise relates to isolated and/or purified nucleotide sequences, characterized in that they are selected from: a) a nucleotide sequence of a specific fragment of the sequence SEQ ID No. 1; b) a nucleotide sequence homologous to a nucleotide sequence such as defined in a); c) a nucleotide sequence complementary to a nucleotide sequence such as defined in a) or b), and a nucleotide sequence of their corresponding RNA; d) a nucleotide sequence capable of hybridizing under stringent conditions with a sequence such as defined in a), b) or c); e) a nucleotide sequence comprising a sequence such as defined in a), b), c) or d); and f) a nucleotide sequence modified by a nucleotide sequence such as defined in a), b), c), d) or e).
Nucleotide, polynucleotide, or nucleic acid sequence will be understood according to the present disclosure as meaning both a double-stranded or single-stranded DNA in the monomeric and dimeric (so-called “in tandem”) forms and the transcription products of said DNAs.
In embodiments, the sequences described herein may be in combination with heterologous sequences. As used herein, “heterologous sequence” refers to sequences which are either artificial (not found in nature) as well as sequences that are not found in Alicyclobacillus acidocaldarius directly connected to the sequences from Alicyclobacillus acidocaldarius described herein. Thus, any sequence, when added to a sequence from Alicyclobacillus acidocaldarius , creates, as a whole, a sequence that is not found in Alicyclobacillus acidocaldarius , is a “heterologous sequence.” Examples of heterologous sequences include, but are not limited to, promoters, enhancers, tags, terminators, and hairpins that are not operatively linked to the sequence from Alicyclobacillus acidocaldarius as found in nature.
Aspects of the disclosure relate to nucleotide sequences which it has been possible to isolate, purify or partially purify, starting from separation methods such as, for example, ion-exchange chromatography, by exclusion based on molecular size, or by affinity, or alternatively fractionation techniques based on solubility in different solvents, or starting from methods of genetic engineering such as amplification, cloning, and subcloning, it being possible for the sequences of the invention to be carried by vectors.
Isolated and/or purified nucleotide sequence fragment according to the disclosure will be understood as designating any nucleotide fragment of the genome of Alicyclobacillus acidocaldarius , and may include, by way of non-limiting example, length of at least 8, 12, 20, 25, 50, 75, 100, 200, 300, 400, 500, 1000, or more, consecutive nucleotides of the sequence from which it originates.
Specific fragment of an isolated and/or purified nucleotide sequence according to the disclosure will be understood as designating any nucleotide fragment of the genome of Alicyclobacillus acidocaldarius , having, after alignment and comparison with the corresponding fragments of genomic sequences of Alicyclobacillus acidocaldarius , at least one nucleotide or base of different nature.
Homologous isolated and/or purified nucleotide sequence in the sense of the present disclosure is understood as meaning isolated and/or purified a nucleotide sequence having at least a percentage identity with the bases of a nucleotide sequence according to the invention of at least about 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.6%, or 99.7%, this percentage being purely statistical and it being possible to distribute the differences between the two nucleotide sequences at random and over the whole of their length.
Specific homologous nucleotide sequence in the sense of the present disclosure is understood as meaning a homologous nucleotide sequence having at least one nucleotide sequence of a specific fragment, such as defined above. Said “specific” homologous sequences can comprise, for example, the sequences corresponding to the genomic sequence or to the sequences of its fragments representative of variants of the genome of Alicyclobacillus acidocaldarius . These specific homologous sequences can thus correspond to variations linked to mutations within strains of Alicyclobacillus acidocaldarius , and especially correspond to truncations, substitutions, deletions and/or additions of at least one nucleotide. Said homologous sequences can likewise correspond to variations linked to the degeneracy of the genetic code.
The term “degree or percentage of sequence homology” refers to “degree or percentage of sequence identity between two sequences after optimal alignment” as defined in the present application.
Two amino-acids or nucleotidic sequences are said to be “identical” if the sequence of amino-acids or nucleotidic residues, in the two sequences is the same when aligned for maximum correspondence as described below. Sequence comparisons between two (or more) peptides or polynucleotides are typically performed by comparing sequences of two optimally aligned sequences over a segment or “comparison window” to identify and compare local regions of sequence similarity. Optimal alignment of sequences for comparison may be conducted by the local homology algorithm of Smith and Waterman, Ad. App. Math 2: 482 (1981), by the homology alignment algorithm of Neddleman and Wunsch, J. Mol. Biol. 48: 443 (1970), by the search for similarity method of Pearson and Lipman, Proc. Natl. Acad. Sci . (U.S.A.) 85: 2444 (1988), by computerized implementation of these algorithms (GAP, BESTFIT, FASTA, and TFASTA in the Wisconsin Genetics Software Package, Genetics Computer Group (GCG), 575 Science Dr., Madison, Wis.), or by visual inspection.
“Percentage of sequence identity” (or degree of identity) is determined by comparing two optimally aligned sequences over a comparison window, where the portion of the peptide or polynucleotide sequence in the comparison window may comprise additions or deletions (i.e., gaps) as compared to the reference sequence (which does not comprise additions or deletions) for optimal alignment of the two sequences. The percentage is calculated by determining the number of positions at which the identical amino-acid residue or nucleic acid base occurs in both sequences to yield the number of matched positions, dividing the number of matched positions by the total number of positions in the window of comparison and multiplying the result by 100 to yield the percentage of sequence identity.
The definition of sequence identity given above is the definition that would be used by one of skill in the art. The definition by itself does not need the help of any algorithm, said algorithms being helpful only to achieve the optimal alignments of sequences, rather than the calculation of sequence identity.
From the definition given above, it follows that there is a well-defined and only one value for the sequence identity between two compared sequences which value corresponds to the value obtained for the best or optimal alignment.
In the BLAST N or BLAST P “BLAST 2 sequence,” software which is available in the web site www.ncbi.nlm.nih.gov/gorf/bl2.html, and habitually used by the inventors and in general by the skilled person for comparing and determining the identity between two sequences, gap cost which depends on the sequence length to be compared is directly selected by the software (i.e., 11.2 for substitution matrix BLOSUM-62 for length>85).
Complementary nucleotide sequence of a sequence of the disclosure is understood as meaning any DNA whose nucleotides are complementary to those of the sequence of the disclosure, and whose orientation is reversed (antisense sequence).
Hybridization under conditions of stringency with a nucleotide sequence according to the disclosure is understood as meaning hybridization under conditions of temperature and ionic strength chosen in such a way that they enable the maintenance of the hybridization between two fragments of complementary DNA.
By way of illustration, conditions of great stringency of the hybridization step with the aim of defining the nucleotide fragments described above are advantageously the following.
The hybridization is carried out at a preferential temperature of 65° C. in the presence of SSC buffer, 1×SSC corresponding to 0.15 M NaCl and 0.05 M Na citrate. The washing steps, for example, can be the following: 2×SSC, at ambient temperature followed by two washes with 2×SSC, 0.5% SDS at 65° C.; 2×0.5×SSC, 0.5% SDS; at 65° C. for 10 minutes each.
The conditions of intermediate stringency, using, for example, a temperature of 42° C. in the presence of a 2×SSC buffer, or of less stringency, for example, a temperature of 37° C. in the presence of a 2×SSC buffer, respectively, require a globally less significant complementarity for the hybridization between the two sequences.
The stringent hybridization conditions described above for a polynucleotide with a size of approximately 350 bases will be adapted by the person skilled in the art for oligonucleotides of greater or smaller size, according to the teaching of Sambrook et al., 1989.
Among the isolated and/or purified nucleotide sequences according to the disclosure, are those which can be used as a primer or probe in methods enabling the homologous sequences according to the disclosure to be obtained, these methods, such as the polymerase chain reaction (PCR), nucleic acid cloning, and sequencing, being well known to the person skilled in the art.
Among said isolated and/or purified nucleotide sequences according to the disclosure, those are again preferred which can be used as a primer or probe in methods enabling the presence of SEQ ID No. 1, one of its fragments, or one of its variants such as defined below to be diagnosed.
The nucleotide sequence fragments according to the disclosure can be obtained, for example, by specific amplification, such as PCR, or after digestion with appropriate restriction enzymes of nucleotide sequences according to the invention, these methods in particular being described in the work of Sambrook et al., 1989. Such representative fragments can likewise be obtained by chemical synthesis according to methods well known to persons of ordinary skill in the art.
“Modified nucleotide sequence” will be understood as meaning any nucleotide sequence obtained by mutagenesis according to techniques well known to the person skilled in the art, and containing modifications with respect to the normal sequences according to the disclosure, for example, mutations in the regulatory and/or promoter sequences of polypeptide expression, especially leading to a modification of the rate of expression of said polypeptide or to a modulation of the replicative cycle.
“Modified nucleotide sequence” will likewise be understood as meaning any nucleotide sequence coding for a modified polypeptide such as defined below.
Embodiments of the disclosure likewise relate to isolated and/or purified nucleotide sequences characterized in that they comprise a nucleotide sequence selected from: a) the nucleotide sequence of SEQ ID No. 1, or one of its fragments; b) a nucleotide sequence of a specific fragment of a sequence such as defined in a); c) a homologous nucleotide sequence having at least 90% identity with a sequence such as defined in a) or b); d) a complementary nucleotide sequence or sequence of RNA corresponding to a sequence such as defined in a), b) or c); and e) a nucleotide sequence modified by a sequence such as defined in a), b), c) or d).
Among the isolated and/or purified nucleotide sequences according to the disclosure are the nucleotide sequences of SEQ ID Nos. 8-12, or fragments thereof and any other isolated and/or purified nucleotide sequences which have a homology of at least 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.6%, or 99.7% identity with the sequence SEQ ID No. 1 or fragments thereof. Said homologous sequences can comprise, for example, the sequences corresponding to the genomic sequences Alicyclobacillus acidocaldarius . In the same manner, these specific homologous sequences can correspond to variations linked to mutations within strains of Alicyclobacillus acidocaldarius and especially correspond to truncations, substitutions, deletions and/or additions of at least one nucleotide.
Embodiments of the disclosure comprise the isolated and/or purified polypeptides encoded by a nucleotide sequence according to the disclosure, or fragments thereof, whose sequence is represented by a fragment. Amino acid sequences corresponding to the isolated and/or purified polypeptides can be encoded according to one of the three possible reading frames of the sequence of SEQ ID No. 1.
Embodiments of the disclosure likewise relate to the isolated and/or purified polypeptides, characterized in that they comprise the polypeptide of SEQ No. 2, or one of its fragments.
Among the isolated and/or purified polypeptides, according to embodiments of the disclosure, are the isolated and/or purified polypeptides of the amino acid sequences of SEQ ID Nos. 13-17, or fragments thereof or any other isolated and/or purified polypeptides which have a homology of at least 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.6%, or 99.7% identity with the sequence of SEQ ID No. 2, or fragments thereof.
Embodiments of the disclosure also relate to the polypeptides, characterized in that they comprise a polypeptide selected from: a) a specific fragment of at least 5 amino acids of a polypeptide of an amino acid sequence according to the invention; b) a polypeptide homologous to a polypeptide such as defined in a); c) a specific biologically active fragment of a polypeptide such as defined in a) or b); and d) a polypeptide modified by a polypeptide such as defined in a), b) or c).
In the present description, the terms polypeptide, peptide and protein are interchangeable.
In embodiments of the disclosure, the isolated and/or purified polypeptides according to the disclosure may be glycosylated, pegylated, and/or otherwise post-translationally modified. In further embodiments, glycosylation, pegylation, and/or other post-translational modifications may occur in vivo or in vitro and/or may be performed using chemical techniques. In additional embodiments, any glycosylation, pegylation and/or other post-translational modifications may be N-linked or O-linked.
In embodiments of the disclosure any one of the isolated and/or purified polypeptides according to the disclosure may be enzymatically active at temperatures at or above about 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, and/or 95 degrees Celsius and/or may be enzymatically active at a pH at, below, and/or above 7, 6, 5, 4, 3, 2, 1, and/or 0. In further embodiments of the disclosure, glycosylation, pegylation, and/or other post-translational modification may be required for the isolated and/or purified polypeptides according to the disclosure to be enzymatically active at pH at or below 7, 6, 5, 4, 3, 2, 1, and/or 0 or at temperatures at or above about 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, and/or 95 degrees Celsius.
Aspects of the disclosure relate to polypeptides that are isolated or obtained by purification from natural sources, or else obtained by genetic recombination, or alternatively by chemical synthesis and that they may thus contain unnatural amino acids, as will be described below.
A “polypeptide fragment” according to the embodiments of the disclosure is understood as designating a polypeptide containing at least 5 consecutive amino acids, preferably 10 consecutive amino acids or 15 consecutive amino acids.
In the present disclosure, a specific polypeptide fragment is understood as designating the consecutive polypeptide fragment encoded by a specific fragment nucleotide sequence according to the invention.
“Homologous polypeptide” will be understood as designating the polypeptides having, with respect to the natural polypeptide, certain modifications such as, in particular, a deletion, addition, or substitution of at least one amino acid, a truncation, a prolongation, a chimeric fusion, and/or a mutation. Among the homologous polypeptides, those are preferred whose amino acid sequence has at least 80% or 90%, homology with the sequences of amino acids of polypeptides according to the disclosure.
“Specific homologous polypeptide” will be understood as designating the homologous polypeptides such as defined above and having a specific fragment of polypeptide according to the disclosure.
In the case of a substitution, one or more consecutive or nonconsecutive amino acids are replaced by “equivalent” amino acids. The expression “equivalent” amino acid is directed here at designating any amino acid capable of being substituted by one of the amino acids of the base structure without, however, essentially modifying the biological activities of the corresponding peptides and such that they will be defined by the following. Examples of such substitutions in the amino acid sequence of SEQ ID No. 2 may include those isolated and/or purified polypeptides of the amino acid sequences of SEQ ID Nos. 13-17.
These equivalent amino acids can be determined either by depending on their structural homology with the amino acids which they substitute, or on results of comparative tests of biological activity between the different polypeptides, which are capable of being carried out.
By way of nonlimiting example, the possibilities of substitutions capable of being carried out without resulting in an extensive modification of the biological activity of the corresponding modified polypeptides will be mentioned, the replacement, for example, of leucine by valine or isoleucine, of aspartic acid by glutamic acid, of glutamine by asparagine, of arginine by lysine etc., the reverse substitutions naturally being envisageable under the same conditions.
In a further embodiment, substitutions are limited to substitutions in amino acids not conserved among other proteins which have similar identified enzymatic activity. For example, the figures herein provide sequence alignments between certain polypeptides of the disclosure and other polypeptides identified as having similar enzymatic activity, with amino acids common to three or more of the sequences aligned as indicated in bold. Thus, according to one embodiment of the disclosure, substitutions or mutations may be made at positions that are not indicated as in bold in figures. Examples of such polypeptides may include, but are not limited to, those found in the amino acid sequences of SEQ ID Nos. 13-17. In a further embodiment, nucleic acid sequences may be mutated or substituted such that the amino acid they encode is unchanged (degenerate substitutions and/or mutations) and/or mutated or substituted such that any resulting amino acid substitutions or mutations are made at positions that are not indicated as in bold in figures. Examples of such nucleic acid sequences may include, but are not limited to, those found in the nucleotide sequences of SEQ ID Nos. 13-17 or fragments thereof.
The specific homologous polypeptides likewise correspond to polypeptides encoded by the specific homologous nucleotide sequences, such as defined above, and thus comprise in the present definition polypeptides which are mutated or correspond to variants which can exist in Alicyclobacillus acidocaldarius , and which especially correspond to truncations, substitutions, deletions, and/or additions of at least one amino acid residue.
“Specific biologically active fragment of a polypeptide,” according to an embodiment of the disclosure will be understood in particular as designating a specific polypeptide fragment, such as defined above, having at least one of the characteristics of polypeptides according to the disclosure. In certain embodiments the peptide is capable of acting as an Acetylxylan esterase.
The polypeptide fragments according to embodiments of the disclosure can correspond to isolated or purified fragments naturally present in a Alicyclobacillus acidocaldarius or correspond to fragments which can be obtained by cleavage of said polypeptide by a proteolytic enzyme, such as trypsin or chymotrypsin or collagenase, or by a chemical reagent, such as cyanogen bromide (CNBr). Such polypeptide fragments can likewise just as easily be prepared by chemical synthesis, from hosts transformed by an expression vector according to the disclosure containing a nucleic acid enabling the expression of said fragments, placed under the control of appropriate regulation and/or expression elements.
“Modified polypeptide” of a polypeptide according to an embodiment of the disclosure is understood as designating a polypeptide obtained by genetic recombination or by chemical synthesis as will be described below, having at least one modification with respect to the normal sequence. These modifications may or may not be able to bear on amino acids at the origin of specificity, and/or of activity, or at the origin of the structural conformation, localization, and of the capacity of membrane insertion of the polypeptide according to the disclosure. It will thus be possible to create polypeptides of equivalent, increased, or decreased activity, and of equivalent, narrower, or wider specificity. Among the modified polypeptides, it is necessary to mention the polypeptides in which up to 5 amino acids can be modified, truncated at the N- or C-terminal end, or even deleted or added.
The methods enabling said modulations on eukaryotic or prokaryotic cells to be demonstrated are well known to the person of ordinary skill in the art. It is likewise well understood that it will be possible to use the nucleotide sequences coding for said modified polypeptides for said modulations, for example, through vectors according to the disclosure and described below.
The preceding modified polypeptides can be obtained by using combinatorial chemistry, in which it is possible to systematically vary parts of the polypeptide before testing them on models, cell cultures or microorganisms, for example, to select the compounds which are most active or have the properties sought.
Chemical synthesis likewise has the advantage of being able to use unnatural amino acids, or nonpeptide bonds.
Thus, in order to improve the duration of life of the polypeptides according to the disclosure, it may be of interest to use unnatural amino acids, for example, in D form, or else amino acid analogs, especially sulfur-containing forms, for example.
Finally, it will be possible to integrate the structure of the polypeptides according to the disclosure, its specific or modified homologous forms, into chemical structures of polypeptide types or others. Thus, it may be of interest to provide at the N- and C-terminal ends compounds not recognized by proteases.
The nucleotide sequences coding for a polypeptide according to the disclosure are likewise part of the disclosure.
The disclosure likewise relates to nucleotide sequences utilizable as a primer or probe, characterized in that said sequences are selected from the nucleotide sequences according to the disclosure.
It is well understood that the present disclosure, in various embodiments, likewise relates to specific polypeptides of Alicyclobacillus acidocaldarius , encoded by nucleotide sequences, capable of being obtained by purification from natural polypeptides, by genetic recombination or by chemical synthesis by procedures well known to the person skilled in the art and such as described in particular below. In the same manner, the labeled or unlabeled mono- or polyclonal antibodies directed against said specific polypeptides encoded by said nucleotide sequences are also encompassed by the disclosure.
Embodiments of the disclosure additionally relate to the use of a nucleotide sequence according to the disclosure as a primer or probe for the detection and/or the amplification of nucleic acid sequences.
The nucleotide sequences according to embodiments of the disclosure can thus be used to amplify nucleotide sequences, especially by the PCR technique (polymerase chain reaction) (Erlich, 1989; Innis et al., 1990; Rolfs et al., 1991; and White et al., 1997).
These oligodeoxyribonucleotide or oligoribonucleotide primers advantageously have a length of at least 8 nucleotides, preferably of at least 12 nucleotides, and even more preferentially at least 20 nucleotides.
Other amplification techniques of the target nucleic acid can be advantageously employed as alternatives to PCR.
The nucleotide sequences of the disclosure, in particular the primers according to the disclosure, can likewise be employed in other procedures of amplification of a target nucleic acid, such as: the TAS technique (Transcription-based Amplification System), described by Kwoh et al. in 1989; the 3SR technique (Self-Sustained Sequence Replication), described by Guatelli et al. in 1990; the NASBA technique (Nucleic Acid Sequence Based Amplification), described by Kievitis et al. in 1991; the SDA technique (Strand Displacement Amplification) (Walker et al., 1992); the TMA technique (Transcription Mediated Amplification).
The polynucleotides of the disclosure can also be employed in techniques of amplification or of modification of the nucleic acid serving as a probe, such as: the LCR technique (Ligase Chain Reaction), described by Landegren et al. in 1988 and improved by Barany et al. in 1991, which employs a thermostable ligase; the RCR technique (Repair Chain Reaction), described by Segev in 1992; the CPR technique (Cycling Probe Reaction), described by Duck et al. in 1990; the amplification technique with Q-beta replicase, described by Miele et al. in 1983 and especially improved by Chu et al. in 1986, Lizardi et al. in 1988, then by Burg et al., as well as by Stone et al. in 1996.
In the case where the target polynucleotide to be detected is possibly an RNA, for example, an mRNA, it will be possible to use, prior to the employment of an amplification reaction with the aid of at least one primer according to the invention or to the employment of a detection procedure with the aid of at least one probe of the disclosure, an enzyme of reverse transcriptase type in order to obtain a cDNA from the RNA contained in the biological sample. The cDNA obtained will thus serve as a target for the primer(s) or the probe(s) employed in the amplification or detection procedure according to the disclosure.
The detection probe will be chosen in such a manner that it hybridizes with the target sequence or the amplicon generated from the target sequence. By way of sequence, such a probe will advantageously have a sequence of at least 12 nucleotides, in particular of at least 20 nucleotides, and preferably of at least 100 nucleotides.
Embodiments of the disclosure also comprise the nucleotide sequences utilizable as a probe or primer according to the disclosure, characterized in that they are labeled with a radioactive compound or with a nonradioactive compound.
The unlabeled nucleotide sequences can be used directly as probes or primers, although the sequences are generally labeled with a radioactive element ( 32 P, 35 S, 3 H, 125 I) or with a nonradioactive molecule (biotin, acetylaminofluorene, digoxigenin, 5-bromodeoxyuridine, fluorescein) to obtain probes which are utilizable for numerous applications.
Examples of nonradioactive labeling of nucleotide sequences are described, for example, in French Patent No. 7810975 or by Urdea et al. or by Sanchez-Pescador et al. in 1988.
In the latter case, it will also be possible to use one of the labeling methods described in patents FR-2 422 956 and FR-2 518 755.
The hybridization technique can be carried out in various manners (Matthews et al., 1988). The most general method consists in immobilizing the nucleic acid extract of cells on a support (such as nitrocellulose, nylon, polystyrene) and in incubating, under well-defined conditions, the immobilized target nucleic acid with the probe. After hybridization, the excess of probe is eliminated and the hybrid molecules formed are detected by the appropriate method (measurement of the radioactivity, of the fluorescence or of the enzymatic activity linked to the probe).
The disclosure, in various embodiments, likewise comprises the nucleotide sequences according to the disclosure, characterized in that they are immobilized on a support, covalently or noncovalently.
According to another advantageous mode of employing nucleotide sequences according to the disclosure, the latter can be used immobilized on a support and can thus serve to capture, by specific hybridization, the target nucleic acid obtained from the biological sample to be tested. If necessary, the solid support is separated from the sample and the hybridization complex formed between said capture probe and the target nucleic acid is then detected with the aid of a second probe, a so-called “detection probe,” labeled with an easily detectable element.
Another aspect of the present disclosure is a vector for the cloning and/or expression of a sequence, characterized in that it contains a nucleotide sequence according to the invention.
The vectors according to the disclosure, characterized in that they contain the elements enabling the expression and/or the secretion of said nucleotide sequences in a determined host cell, are likewise part of the disclosure.
The vector may then contain a promoter, signals of initiation and termination of translation, as well as appropriate regions of regulation of transcription. It may be able to be maintained stably in the host cell and can optionally have particular signals specifying the secretion of the translated protein. These different elements may be chosen as a function of the host cell used. To this end, the nucleotide sequences according to the disclosure may be inserted into autonomous replication vectors within the chosen host, or integrated vectors of the chosen host.
Such vectors will be prepared according to the methods currently used by the person skilled in the art, and it will be possible to introduce the clones resulting therefrom into an appropriate host by standard methods, such as, for example, lipofection, electroporation, and thermal shock.
The vectors according to the disclosure are, for example, vectors of plasmid or viral origin. One example of a vector for the expression of polypeptides of the disclosure is baculovirus.
These vectors are useful for transforming host cells in order to clone or to express the nucleotide sequences of the disclosure.
The invention likewise comprises the host cells transformed by a vector according to the disclosure.
These cells can be obtained by the introduction into host cells of a nucleotide sequence inserted into a vector such as defined above, then the culturing of said cells under conditions allowing the replication and/or expression of the transfected nucleotide sequence.
The host cell can be selected from prokaryotic or eukaryotic systems, such as, for example, bacterial cells (Olins and Lee, 1993), but likewise yeast cells (Buckholz, 1993), as well as plant cells, such as Arabidopsis sp., and animal cells, in particular the cultures of mammalian cells (Edwards and Aruffo, 1993), for example, Chinese hamster ovary (CHO) cells, but likewise the cells of insects in which it is possible to use procedures employing baculoviruses, for example, Sf9 insect cells (Luckow, 1993).
Embodiments of the disclosure likewise relate to organisms comprising one of said transformed cells according to the disclosure.
The obtainment of transgenic organisms according to the disclosure overexpressing one or more of the genes of Alicyclobacillus acidocaldarius or part of the genes may be carried out in, for example, rats, mice, or rabbits according to methods well known to the person skilled in the art, such as by viral or nonviral transfections. It will be possible to obtain the transgenic organisms overexpressing one or more of said genes by transfection of multiple copies of said genes under the control of a strong promoter of ubiquitous nature, or selective for one type of tissue. It will likewise be possible to obtain the transgenic organisms by homologous recombination in embryonic cell strains, transfer of these cell strains to embryos, selection of the affected chimeras at the level of the reproductive lines, and growth of said chimeras.
The transformed cells as well as the transgenic organisms according to the disclosure are utilizable in procedures for preparation of recombinant polypeptides.
It is today possible to produce recombinant polypeptides in a relatively large quantity by genetic engineering using the cells transformed by expression vectors according to the disclosure or using transgenic organisms according to the disclosure.
The procedures for preparation of a polypeptide of the disclosure in recombinant form, characterized in that they employ a vector and/or a cell transformed by a vector according to the disclosure and/or a transgenic organism comprising one of said transformed cells according to the disclosure are themselves comprised in the present disclosure.
As used herein, “transformation” and “transformed” relate to the introduction of nucleic acids into a cell, whether prokaryotic or eukaryotic. Further, “transformation” and “transformed,” as used herein, need not relate to growth control or growth deregulation.
Among said procedures for preparation of a polypeptide of the disclosure in recombinant form, the preparation procedures include employing a vector, and/or a cell transformed by said vector and/or a transgenic organism comprising one of said transformed cells, containing a nucleotide sequence according to the disclosure of coding for a polypeptide of Alicyclobacillus acidocaldarius.
A variant according to the disclosure may consist of producing a recombinant polypeptide fused to a “carrier” protein (chimeric protein). The advantage of this system is that it may enable stabilization of and/or a decrease in the proteolysis of the recombinant product, an increase in the solubility in the course of renaturation in vitro and/or a simplification of the purification when the fusion partner has an affinity for a specific ligand.
More particularly, the disclosure relates to a procedure for preparation of a polypeptide of the invention comprising the following acts: a) culture of transformed cells under conditions allowing the expression of a recombinant polypeptide of a nucleotide sequence according to the disclosure; and b) if need be, recovery of said recombinant polypeptide.
When the procedure for preparation of a polypeptide of the disclosure employs a transgenic organism according to the disclosure, the recombinant polypeptide is then extracted from said organism.
The disclosure also relates to a polypeptide, which is capable of being obtained by a procedure of the disclosure, such as described previously.
The disclosure also comprises a procedure for preparation of a synthetic polypeptide, characterized in that it uses a sequence of amino acids of polypeptides according to the disclosure.
The disclosure likewise relates to a synthetic polypeptide obtained by a procedure according to the disclosure.
The polypeptides according to the disclosure can likewise be prepared by techniques, which are conventional in the field of the synthesis of peptides. This synthesis can be carried out in homogeneous solution or in solid phase.
For example, recourse can be made to the technique of synthesis in homogeneous solution described by Houben-Weyl in 1974.
This method of synthesis consists in successively condensing, two-by-two, the successive amino acids in the order required, or in condensing amino acids and fragments formed previously and already containing several amino acids in the appropriate order, or alternatively several fragments previously prepared in this way, it being understood that it will be necessary to protect beforehand all the reactive functions carried by these amino acids or fragments, with the exception of amine functions of one and carboxyls of the other or vice-versa, which must normally be involved in the formation of peptide bonds, especially after activation of the carboxyl function, according to the methods well known in the synthesis of peptides.
Recourse may also be made to the technique described by Merrifield.
To make a peptide chain according to the Merrifield procedure, recourse is made to a very porous polymeric resin, on which is immobilized the first C-terminal amino acid of the chain. This amino acid is immobilized on a resin through its carboxyl group and its amine function is protected. The amino acids that are going to form the peptide chain are thus immobilized, one after the other, on the amino group, which is deprotected beforehand each time, of the portion of the peptide chain already formed, and which is attached to the resin. When the whole of the desired peptide chain has been formed, the protective groups of the different amino acids forming the peptide chain are eliminated and the peptide is detached from the resin with the aid of an acid.
The disclosure additionally relates to hybrid polypeptides having at least one polypeptide according to the disclosure, and a sequence of a polypeptide capable of inducing an immune response in man or animals.
Advantageously, the antigenic determinant is such that it is capable of inducing a humoral and/or cellular response.
It will be possible for such a determinant to comprise a polypeptide according to the disclosure in a glycosylated, pegylated, and/or otherwise post-translationally modified form used with a view to obtaining immunogenic compositions capable of inducing the synthesis of antibodies directed against multiple epitopes.
These hybrid molecules can be formed, in part, of a polypeptide carrier molecule or of fragments thereof according to the disclosure, associated with a possibly immunogenic part, in particular an epitope of the diphtheria toxin, the tetanus toxin, a surface antigen of the hepatitis B virus (patent FR 79 21811), the VP1 antigen of the poliomyelitis virus or any other viral or bacterial toxin or antigen.
The procedures for synthesis of hybrid molecules encompass the methods used in genetic engineering for constructing hybrid nucleotide sequences coding for the polypeptide sequences sought. It will be possible, for example, to refer advantageously to the technique for obtainment of genes coding for fusion proteins described by Minton in 1984.
Said hybrid nucleotide sequences coding for a hybrid polypeptide as well as the hybrid polypeptides according to the disclosure characterized in that they are recombinant polypeptides obtained by the expression of said hybrid nucleotide sequences are likewise part of the disclosure.
The disclosure likewise comprises the vectors characterized in that they contain one of said hybrid nucleotide sequences. The host cells transformed by said vectors, the transgenic organisms comprising one of said transformed cells as well as the procedures for preparation of recombinant polypeptides using said vectors, said transformed cells and/or said transgenic organisms are, of course, likewise part of the disclosure.
The polypeptides according to the disclosure, the antibodies according to the disclosure described below and the nucleotide sequences according to the disclosure can advantageously be employed in procedures for the detection and/or identification of Alicyclobacillus acidocaldarius , in a sample capable of containing them. These procedures, according to the specificity of the polypeptides, the antibodies and the nucleotide sequences according to the invention which will be used, will in particular be able to detect and/or to identify an Alicyclobacillus acidocaldarius.
The polypeptides according to the disclosure can advantageously be employed in a procedure for the detection and/or the identification of Alicyclobacillus acidocaldarius in a sample capable of containing them, characterized in that it comprises the following acts: a) contacting of this sample with a polypeptide or one of its fragments according to the disclosure (under conditions allowing an immunological reaction between said polypeptide and the antibodies possibly present in the biological sample); and b) demonstration of the antigen-antibody complexes possibly formed.
Any conventional procedure can be employed for carrying out such a detection of the antigen-antibody complexes possibly formed.
By way of example, a preferred method brings into play immunoenzymatic processes according to the ELISA technique, by immunofluorescence, or radioimmunological assay processes (RIA) or their equivalent.
Thus, the disclosure likewise relates to the polypeptides according to the disclosure, labeled with the aid of an adequate label such as of the enzymatic, fluorescent or radioactive type.
Such methods comprise, for example, the following acts: deposition of determined quantities of a polypeptide composition according to the disclosure in the wells of a microtiter plate, introduction into said wells of increasing dilutions of serum, or of a biological sample other than that defined previously, having to be analyzed, incubation of the microplate, introduction into the wells of the microtiter plate of labeled antibodies directed against pig immunoglobulins, the labeling of these antibodies having been carried out with the aid of an enzyme selected from those which are capable of hydrolyzing a substrate by modifying the absorption of the radiation of the latter, at least at a determined wavelength, for example, at 550 nm, detection, by comparison with a control test, of the quantity of hydrolyzed substrate.
The polypeptides according to the disclosure enable monoclonal or polyclonal antibodies to be prepared which are characterized in that they specifically recognize the polypeptides according to the disclosure. It will advantageously be possible to prepare the monoclonal antibodies from hybridomas according to the technique described by Köhler and Milstein in 1975. It will be possible to prepare the polyclonal antibodies, for example, by immunization of an animal, in particular a mouse, with a polypeptide or a DNA, according to the disclosure, associated with an adjuvant of the immune response, and then purification of the specific antibodies contained in the serum of the immunized animals on an affinity column on which the polypeptide which has served as an antigen has previously been immobilized. The polyclonal antibodies according to the disclosure can also be prepared by purification, on an affinity column on which a polypeptide according to the disclosure has previously been immobilized, of the antibodies contained in the serum of an animal immunologically challenged by Alicyclobacillus acidocaldarius , or a polypeptide or fragment according to the disclosure.
The disclosure likewise relates to mono- or polyclonal antibodies or their fragments, or chimeric antibodies, characterized in that they are capable of specifically recognizing a polypeptide according to the disclosure.
It will likewise be possible for the antibodies of the disclosure to be labeled in the same manner as described previously for the nucleic probes of the disclosure, such as a labeling of enzymatic, fluorescent or radioactive type.
The disclosure is additionally directed at a procedure for the detection and/or identification of Alicyclobacillus acidocaldarius in a sample, characterized in that it comprises the following acts: a) contacting of the sample with a mono- or polyclonal antibody according to the disclosure (under conditions allowing an immunological reaction between said antibodies and the polypeptides of Alicyclobacillus acidocaldarius possibly present in the biological sample); and b) demonstration of the antigen-antibody complex possibly formed.
The present disclosure likewise relates to a procedure for the detection and/or the identification of Alicyclobacillus acidocaldarius in a sample, characterized in that it employs a nucleotide sequence according to the disclosure.
More particularly, the disclosure relates to a procedure for the detection and/or the identification of Alicyclobacillus acidocaldarius in a sample, characterized in that it includes the following acts: a) if need be, isolation of the DNA from the sample to be analyzed; b) specific amplification of the DNA of the sample with the aid of at least one primer, or a pair of primers, according to the disclosure; and c) demonstration of the amplification products.
These can be detected, for example, by the technique of molecular hybridization utilizing a nucleic probe according to the invention. This probe will advantageously be labeled with a nonradioactive (cold probe) or radioactive element.
For the purposes of the present disclosure, “DNA of the biological sample” or “DNA contained in the biological sample” will be understood as meaning either the DNA present in the biological sample considered, or possibly the cDNA obtained after the action of an enzyme of reverse transcriptase type on the RNA present in said biological sample.
A further embodiment of the disclosure comprises a method, characterized in that it comprises the following acts: a) contacting of a nucleotide probe according to the disclosure with a biological sample, the DNA contained in the biological sample having, if need be, previously been made accessible to hybridization under conditions allowing the hybridization of the probe with the DNA of the sample; and b) demonstration of the hybrid formed between the nucleotide probe and the DNA of the biological sample.
The present disclosure also relates to a procedure according to the disclosure, characterized in that it comprises the following acts: a) contacting of a nucleotide probe immobilized on a support according to the disclosure with a biological sample, the DNA of the sample having, if need be, previously been made accessible to hybridization, under conditions allowing the hybridization of the probe with the DNA of the sample; b) contacting of the hybrid formed between the nucleotide probe immobilized on a support and the DNA contained in the biological sample, if need be after elimination of the DNA of the biological sample which has not hybridized with the probe, with a nucleotide probe labeled according to the disclosure; and c) demonstration of the novel hybrid formed in act b).
According to an advantageous embodiment of the procedure for detection and/or identification defined previously, this is characterized in that, prior to act a), the DNA of the biological sample is first amplified with the aid of at least one primer according to the disclosure.
Further embodiments of the disclosure comprise methods of at least partially degrading, cleaving, and/or removing a polysaccharide, lignocellulose, hemicellulose, lignin, chitin, heteroxylan, and/or xylan-decorating group. Degrading, cleaving, and/or removing these structures have in the art recognized utility such as those described in Mielenz 2001; Jeffries 1996; Shallom and Shoham 2003; Lynd et al. 2002; Vieille and Zeikus 2001; Bertoldo et al. 2004; and/or Malherbe and Cloete 2002.
Embodiments of methods include placing a recombinant, purified, and/or isolated polypeptide having at least 90% sequence identity to SEQ ID No. 2 in fluid contact with a polysaccharide, lignocellulose, hemicellulose, lignin, chitin, heteroxylan, and/or xylan-decorating group.
Further embodiments of methods include placing a cell producing or encoding a recombinant, purified, and/or isolated polypeptide having at least 90% sequence identity to SEQ ID No. 2 in fluid contact with a polysaccharide, lignocellulose, hemicellulose, lignin, chitin, heteroxylan, and/or xylan-decorating group.
As used herein, “partially degrading” relates to the rearrangement or cleavage of chemical bonds in the target structure.
In additional embodiments, methods of at least partially degrading, cleaving, and/or removing a polysaccharide, lignocellulose, hemicellulose, lignin, chitin, heteroxylan, and/or xylan-decorating group may take place at temperatures at or above about 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, and/or 95 degrees Celsius and/or at a pH at, below, and/or above 7, 6, 5, 4, 3, 2, 1, and/or 0.
Further embodiments of the disclosure may comprise a kit for at least partially degrading, cleaving, and/or removing a polysaccharide, lignocellulose, hemicellulose, lignin, chitin, heteroxylan, and/or xylan-decorating group, the kit comprising a cell producing or encoding a recombinant, purified, and/or isolated a polypeptide having at least 90% sequence identity to SEQ ID No. 2 and/or a recombinant, purified, and/or isolated a polypeptide having at least 90% sequence identity to SEQ ID No. 2.
The disclosure is described in additional detail in the following illustrative example. Although the example may represent only a selected embodiment of the disclosure, it should be understood that the following example is illustrative and not limiting.
In embodiments of the disclosure any one of the isolated and/or purified polypeptides according to the disclosure may be enzymatically active at temperatures at or above about 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, and/or 95 degrees Celsius and/or may be enzymatically active at a pH at, below, and/or above 7, 6, 5, 4, 3, 2, 1, and/or 0. In further embodiments of the disclosure, glycosylation, pegylation, and/or other post-translational modification may be required for the isolated and/or purified polypeptides according to the invention to be enzymatically active at pH at or below 7, 6, 5, 4, 3, 2, 1, and/or 0 or at temperatures at or above about 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, and/or 95 degrees Celsius.
All references, including publications, patents, and patent applications, 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.
While this disclosure has been described in the context of certain embodiments, the present disclosure can be further modified. This application therefore encompasses any variations, uses, or adaptations of the disclosure using its general principles. Further, this application encompasses such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims and their legal equivalents.
EXAMPLE
Example: RAAC02760: An Acetylxylan Esterase
Provided in SEQ ID NO:1 is a nucleotide sequence isolated from Alicyclobacillus acidocaldarius and encoding the polypeptide of SEQ ID NO:2. As can be seen in FIGS. 1A and 1B , SEQ ID NO:2 aligns well with other proteins identified as esterases. Of particular importance, it is noted that where amino acids are conserved in other esterases, those amino acids are generally conserved in SEQ ID NO:2. Thus, the polypeptide provided in SEQ ID NO:2 is properly classified as an acetylxylan esterase.
The polypeptides of SEQ ID NOs:13-17 are representative examples of conservative substitutions in the polypeptide of SEQ ID NO:2 and are encoded by nucleotide sequences of SEQ ID NOs:8-12, respectively.
The nucleotide sequences of SEQ ID NOs:1 and 8-12 are placed into expression vectors using techniques standard in the art. The vectors are then provided to cells such as bacteria cells or eukaryotic cells such as 519 cells or CHO cells. In conjunction with the normal machinery present in the cells, the vectors comprising SEQ ID NOs: 1 and 8-12 produce the polypeptides of SEQ ID NOs: 2 and 13-17. The polypeptides of SEQ ID NOs: 2 and 13-17 are then isolated and/or purified. The isolated and/or purified polypeptides of SEQ ID NOs: 2 and 13-17 are then demonstrated to have activity as acetylxylan esterases.
The isolated and/or purified polypeptides of SEQ ID NOs: 2 and 13-17 are challenged with xylan or xylo-oligosaccharide. The isolated and/or purified polypeptides of SEQ ID NOs: 2 and 13-17 are demonstrated to have activity as acetylxylan esterases.
FIG. 2 represents the activity of four different preparations of SEQ ID NO: 2. Therein, the activity (units/mg) as an acetylxylan esterase is shown at 10, 15, and 20 minutes. | A genetically modified organism comprising at least one nucleic acid sequence and/or at least one recombinant nucleic acid isolated from Alicyclobacillus acidocaldarius and encoding a polypeptide involved in at least partially degrading, cleaving, transporting, metabolizing, or removing polysaccharide, lignocellulose, hemicellulose, lignin, chitin, heteroxylan, and/or xylan-decorating group; and at least one nucleic acid sequence and/or at least one recombinant nucleic acid encoding a polypeptide involved in fermenting sugar molecules to a product. Additionally, enzymatic and/or proteinaceous extracts may be isolated from one or more genetically modified organisms. The extracts are utilized to convert biomass into a product. Further provided are methods of converting biomass into products comprising: placing the genetically modified organism and/or enzymatic extracts thereof in fluid contact with polysaccharides, cellulose, lignocellulose, hemicellulose, lignin, starch, sugars, sugar oligomers, carbohydrates, complex carbohydrates, chitin, heteroxylans, glycosides, and/or xylan-, glucan-, galactan-, or mannan-decorating groups. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to pile carpet trimming devices, and more particularly to an improved apparatus for beveling carpet edges and forming bas-relief designs or patterns in pile carpet surfaces.
Pile carpet inlays and bas-relief carpet designs have become an increasingly popular alternative to custom carpet manufacture due to the obvious differences in both cost and design restrictions. Designs can be created and inlays highlighted by using trimming and/or beveling techniques on pile carpet surfaces to produce variations in the carpet pile height. Also, finished edges are produced by beveling prior to the addition of trim material to the fringe. Such techniques usually are performed on the carpet surface and edges with the use of pneumatic or electric shears having a pair of toothed blade members which laterally reciprocally move relative to one another for engagement of the teeth thereon with the designated carpet pile.
U.S. Pat. No. 2,088,162 discloses a pile carpet trimming and beveling apparatus comprising electrically powered shears that are vertically and rotatably adjustably attached to a base plate for producing carpet designs with varying pile depths and angular cuts. This prior art, however, is not particularly suited for trimming carpet edges, and utilizes intricately assembled parts which would be too expensive competitively to produce in today's marketplace. The U.S. Pat. No. 4,970,790 also discloses pile carpet carving apparatus comprising a pile cutter or trimming device pivotally mounted above a base plate for vertical and angular adjustment thereof for producing designs having varying depths and angular cuts. Such an assembly, however, also lacks any means for controlling the uniform beveling of the carpet edge, and is limited with regard to the maximum attainable beveling angle.
It is therefore an object of this invention to provide improved pile carpet trimming and beveling apparatus which is capable of performing uniform beveling of a pile carpet edge.
It is also an object of this invention to provide carpet trimming and beveling apparatus of the type described which is capable of producing infinitely adjustable cuts of varying depth and angle.
Still another object of this invention is to provide for apparatus of the type described a roller-mounted base plate for expediting bevel edging operations.
Other objects of this invention will become apparent hereinafter from the specification and the recital of the appended claims, particularly when read in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
Each embodiment of this invention is intended to be used with any conventional pile carpet cutter or trimming device. The apparatus comprises a heavy, roller-mounted base plate having an opening therein disposed to provide the shearing head of a conventional trimming device access to the surface of a carpet. A support stand is slidably mounted to the upper surface of the base plate for selective lateral adjustment towards or away from the opening. Projecting from one side of the support stand rearwardly of the opening is a clamp fixture having adjustably mounted therein the housing of a conventional trimming device. The clamp fixture is mounted on the support stand for pivotal adjustment about a horizontal axis, thereby permitting the head of the trimming device to be swung vertically relative to the access opening in the base plate. The housing of the trimming device is also rotatably adjustable within the clamp fixture. Collectively, these adjustable features of the trimming device allow the assembly effectively to operate on both the surface and edges of a pile carpet.
Also attached to the base plate adjacent opposite ends of its pile access opening are two, linearly aligned guide members, which facilitate the beveling operation on carpet edges. Attached to the lead guide member is a retention bracket whose position thereon may be vertically adjusted, such that a generally planar retainer thereon may be positioned to engage the surface of carpets of varying thickness for the purpose of preventing any bunching or folding of the carpet edge which could disrupt the edge-beveling operation. Together, the guide members and the retention bracket provide a means for maintaining a uniformly beveled linear cut to the carpet edge.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a bevel-trimmer assembly made according to one embodiment of the present invention;
FIG. 2 is a side elevational view of this assembly taken generally along line 2--2 of FIG. 1 looking in the direction of the arrows, with a portion of the base plate being broken away and shown in section, and with the trimming head being shown in phantom as it appears after being adjusted to perform a uniform depth cut in the pile surface of a carpet;
FIG. 3 is a rear elevational view of the assembly as seen when viewing the right end of the apparatus as shown in FIG. 2, and with portions thereof being broken away and shown in section; and
FIG. 4 is a rear elevational view similar to FIG. 3, but showing the trimming device as it appears in use performing a beveled cut to the edge of a carpet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings by numerals of reference, and first to FIGS. 1-3, 10 denotes generally the improved carpet trimming and beveling apparatus; and 11 denotes generally a conventional trimming device which forms part of this apparatus. Trimming device 11 may be any electrically or pneumatically powered carpet trimmer, such as for example the pneumatic carpet trimming device disclosed in my U.S. Pat. No. Re33,756.
Apparatus 10 includes also an elongate polygonal base plate 12 having parallel, planar upper and lower surfaces 13 and 14, respectively. Rotatably supported by conventional ball retainers 16 in each of four rectangularly spaced recesses in the underside of plate 12 are four ball casters 17, each of which projects slightly beneath the plane bottom surface 14 of plate 12. Base plate 12 also has therethrough a rectangular opening 19, which is slightly laterally offset from the longitudinal centerline A (FIG. 1) of the plate, and a pair of identical, parallel slots 21 and 22 which extend perpendicular to axis A. Attached to the upper surface 13 of base plate 12 to extend vertically upwardly therefrom and transversely across the upper ends of slots 21 and 22 is a support stand or plate 24. Plate 24 is adjustably secured to plate 12 by bolts 25 (FIGS. 1 and 3) the shanks of which extend through slots 21 and 22 and thread into the lower edge of plate 24. Loosening of the bolts 25 allows stand 24 to be selectively and slidably moved in a lateral direction, either towards or away from opening 19 for a purpose to be noted hereinafter.
Numeral 26 denotes generally a clamp fixture which is pivotally secured to support stand 24 for adjustment about an axis positioned above and parallel to plate 12 and its slots 21 and 22. Fixture 26 comprises two complimentary plate members 27 and 28, one of which, plate 27, is pivotally attached to stand 24 by a pair of spaced, parallel bolts 29 and 30, each of which threads at its inner end into one side edge of member 27. Intermediate their ends bolts 29 and 30 extend through respective openings 31 and 32 in plate 24, and have conventional wing nuts 33 threaded onto the outer ends thereof As shown more clearly in FIGS. 2 and 3, opening 31 in plate 24 is an elongate, arcuate slot disposed coaxially of the axis of bolt 30, and opening 32 is a circular bore having a diameter slightly larger than that of bolt 30. As a consequence, when wing nuts 33 are loosened, as noted hereinafter, the entire clamp fixture 26 may be pivotally adjusted for approximately 90° about the axis of bolt 30.
The clamp plate member 28 is attached to the complimentary member 27 by means of a pair of bolts 37 and 38, which are threaded at their inner ends into the edge of member 27 remote from plate 24, and which pass intermediate their ends through, and in slightly radially spaced relation to the walls of, parallel cylindrical bores 39 and 40 that extend completely through member 28. Bolts 37 and 38 also have externally threaded outer ends upon which conventional wing nuts 33 are adjustably threaded The complimentary members 27 and 28 have in their confronting edges semicircular recesses 42 and 43, respectively, such that when the members 27 and 28 are bolted together in confronting relation, recesses 42 and 43 form a circular aperture. Conformably seated within the confronting recesses 42 and 43 for rotatable adjustment therein are two, identical, arcuate gripping members 45 and 46 (FIGS. 3 and 4) having outer peripheries similar to recesses 42 and 43, and which have in their confronting sides semi-oval recesses that collectively form a generally oval receptacle 47 disposed circumferentially to engage the body 48 of the trimming device 11. Device 11 is secured within the clamp fixture 26 by first loosening the wing nuts 33 on bolts 37 and 38, and moving the member 28 away from the complimentary member 27 for a distance sufficient to allow housing 48 of the device to be placed into the generally oval receptacle 47 formed by the gripping members 45 and 46, and then tightening the wing nuts 33 on bolts 37 and 38 so that the device 11 is immovable within the gripping members 45 and 46.
Also attached to the upper surface 13 of base plate 12 are spaced guide members 49 and 50. Guide member 49 extends from the leading edge of plate 12 (left edge as shown in FIG. 1) to the opening 19, and has an upright planar face 52 lying in a plane normal to the plate surface 13, and parallel to axis A. Guide member 50 extends from the opening 19 to the rear edge of plate 12 and has an upright planar face 53 also lying in a plane parallel to axis A and in coplanar relation to face 52. The guide members 49 and 50 are generally L-shaped in cross sectional configuration and have base sections 55 and 56, respectively, which are anchored to the upper surface 13 of plate 12 by screws 57.
Slidably attached to the face 52 of guide member 49 near the lead edge of base plate 12 is a bracket 58, which is adjustable downwardly towards or upwardly away from the plate surface 13. Bracket 58 comprises a vertically disposed mounting section 59 that has therein a pair of parallel slots 60 (FIG. 2) for accommodating the screws 61 which secure the bracket to the face 52 of guide member 49, and a horizontally disposed, nearly planar, L-shaped retainer section 62 that projects perpendicularly outwardly from face 52 parallel to the upper surface 13 of plate 12. Retainer 62 has a slightly inclined inner end 63 that points in the direction of trimming device 11, and which as shown in FIG. 2 is bent slightly upwardly.
The carpet trimming apparatus 10 has preferentially been designed to create evenly beveled carpet edges by utilizing the guide members 49 and 50 to align the carpet edge, and the bracket 58 to retain the carpet against upper plate surface 13. In addition, by using a heavy base plate 12 with opening 19 and a slidably adjustable support stand 24, the apparatus 10 also provides exceptional capabilities in performing uniform depth trimming and internal beveling operations. In use, therefore, each of these operations may be performed after making minor adjustments to the carpet trimming apparatus 10.
For producing uniform depth cuts into the pile surface P of a carpet C, the apparatus is placed on top of the carpet (FIG. 2) with the lower surface 14 of plate 12 resting on the pile surface. The wing nuts 33 surrounding bolts 29 and 30 are loosened to allow clamp 26 to pivot downwardly about bolt 30 such that the shearing head H of the trimming device 11 is swung from its inoperative position (solid lines in FIG. 2) to a position as shown in phantom where it contacts the carpet pile at a desired depth. The wing nuts 33 are then tightened about bolts 29 and 30, thereby locking clamp 26 in the desired position. Device 11 is then turned on to cause the toothed blade members in head H to reciprocate relative to one another, and the heavy plate 12 is slid along the pile surface P in a predetermined course thereby to create a desired pattern. During this movement the casters 17 perform no significant function, and do not project far enough from beneath the plate surface 14 to impede motion of plate 12.
For producing beveled cuts in the pile surface of the carpet, the plate 12 is placed on top of the carpet pile, and the wing nuts 33 on bolts 37 and 38 are loosened to allow members 45 and 46, and hence trimming device 11 manually to be rotated such that the cutting edge of head H is no longer parallel to base plate 12. Once the desired angular displacement is reached, nuts 33 may be tightened around bolts 37 and 38, and the clamp 26 may be pivoted downwardly and locked in place when the cutting head H has reached a desirable depth in the carpet pile P. Again, the device 11 may then be turned on and the plate 12 guided along a predetermined course on the pile surface in order to create the desired pattern.
In cases where the desired bevel angle is quite large, the rotational adjustment of housing 48 may disrupt the alignment of the cutting head H with the opening 19 in base plate 12. To compensate for any such misalignment, the bolts or screws 25 may be loosened to allow support stand 24 to be moved away from opening 19 such that the cutting head may again be aligned with opening 19. Once properly realigned, the stand 24 may be releasably retained in its new position until further operations warrant its change.
For beveled cuts to the carpet edge (FIG. 4), the casters 17 of plate 12 are positioned on the floor F beneath one edge of the carpet C so that a portion of the carpet overlies a portion of plate 12. This one edge of the carpet is positioned against guide members 49 and 50 such that the edge partially covers the opening 19. Once thus aligned, the carpet is retained against the upper surface 13 of base plate 12 by means of the adjustable bracket 58, which is vertically adjusted so that retainer 62 thereon is pressed into contact with the pile surface of the carpet. This will insure that the carpet edge does not bunch or fold prior to reaching the cutting head of trimming device 11. After fixing the retainer 62 in place, the bevel angle may be selected by rotatably adjusting the gripping members 45 and 46 and consequently device 11 as previously described, and then the device is pivoted to place its head H into engagement with the carpet. Once the desired adjustments have been made, device 11 may be turned on and the plate 12 is rolled along the floor F on its casters 17 for the entire length of the particular carpet edge. It is important to note that once the beveling operation has begun, it is imperative that the carpet edge maintain contact with both guide members 49 and 50 in order to insure that the carpet edge is uniformly beveled in a linear fashion.
Although this invention has been described in connection with a pair of gripping members 45 and 46 which define an oval receptacle 47, it should be apparent to one skilled in the art that the receptacle 47 may take on any shape or form which will accommodate the body of a conventional trimming device 11, and that this embodiment has been described in connection with only one such conventional trimming device. Also, it should be noted that although the bracket 58 has been described in connection with a particularly shaped retainer 62, it should apparent to one skilled in the art that the retainer 62 may take on alternative forms which will perform the same function equally as well. Furthermore, it is important to use a heavy base plate 12 to assure accurate trimming and beveling, and although the plate has been shown to be mounted on roller casters, it will be apparent that other types of rollers or wheels may be utilized without departing from this invention. Also, the edge guiding surfaces or faces 52 and 53 could be shaped to lie in an arcuate plane or path if the edge of a circular carpet, or the like, is to be beveled.
While this invention has been illustrated and described in detail in connection with only certain embodiments thereof, it will be apparent that it is still capable of further modification, and that this application is intended to cover any such modifications as may fall within the scope of one skilled in the art or the appended claims. | A heavy, roller-mounted base plate has thereon a conventional pile carpet trimmer having a shearing head disposed to be swung into and out of a pile access opening in the base plate either to trim the pile of a carpet by sliding the plate on top of the pile, or to bevel the carpet edge by sliding the plate beneath and along one edge of the carpet. Attached to the plate adjacent opposite ends of its pile access opening are two, linearly aligned guide members, which slidably engage a carpet edge during a beveling operation. A retention bracket projects from one of the guide members to overlie the pile surface to prevent any bunching or folding of the carpet edge during the edge-beveling operation. | 3 |
[0001] This invention relates to integrated MEMS transducers having a MEMS transducer structure integrated with associated circuitry on a monolithic die, and to methods of fabricating such integrated MEMS transducers.
BACKGROUND
[0002] Consumer electronics devices are continually getting smaller and, with advances in technology, are gaining increasing performance and functionality. This is clearly evident in the technology used in consumer electronic products such as mobile phones, laptop computers, MP3 players and personal digital assistants (PDAs). Requirements of the mobile phone industry for example, are driving the components to become smaller, yet with higher functionality and reduced cost. It is therefore desirable to integrate functions of electronic circuits together and combine them with transducer devices such as microphones and speakers.
[0003] The result of this is the emergence of micro-electrical-mechanical-systems (MEMS) based transducer devices. These may be for example, capacitive transducers for detecting and/or generating pressure/sound waves or transducers for detecting acceleration. There is a continual drive to reduce the size and cost of these devices through integration with the electronic circuitry necessary to operate and process the information from the MEMS through the removal of the transducer-electronic interfaces. One of the challenges in reaching these goals is the difficulty of achieving compatibility with standard processes used to fabricate complementary-metal-oxide-semiconductor (CMOS) electronic devices during manufacture of MEMS devices. This is required to allow integration of MEMS devices directly with conventional electronics using the same materials and processing machinery. This invention seeks to address this area.
[0004] Microphone devices formed using MEMS fabrication processes typically comprise one or more membranes with electrodes for read-out/drive deposited on the membranes and/or a substrate. In the case of MEMS pressure sensors and microphones, the read out is usually accomplished by measuring the capacitance between a pair of electrodes which will vary as the distance between the electrodes changes in response to sound waves incident on the membrane surface.
[0005] FIGS. 1 a and 1 b show a schematic diagram and a perspective view, respectively, of a known capacitive MEMS microphone device 100 . The capacitive microphone device 100 comprises a membrane layer 101 which forms a flexible membrane which is free to move in response to pressure differences generated by sound waves. A first electrode 102 is mechanically coupled to the flexible membrane, and together they form a first capacitive plate of the capacitive microphone device. A second electrode 103 is mechanically coupled to a generally rigid structural layer or back-plate 104 , which together form a second capacitive plate of the capacitive microphone device. In the example shown in FIG. 1 a the second electrode 103 is embedded within the back-plate structure 104 .
[0006] The capacitive microphone is formed on a substrate 105 , for example a silicon wafer which may have upper and lower oxide layers 106 , 107 formed thereon. A cavity 108 in the substrate and in any overlying layers (hereinafter referred to as a substrate cavity) is provided below the membrane, and may be formed using a “back-etch” through the substrate 105 . The substrate cavity 108 connects to a first cavity 109 located directly below the membrane. These cavities 108 and 109 may collectively provide an acoustic volume thus allowing movement of the membrane in response to an acoustic stimulus. Interposed between the first and second electrodes 102 and 103 is a second cavity 110 .
[0007] The first cavity 109 may be formed using a first sacrificial layer during the fabrication process, i.e. using a material to define the first cavity which can subsequently be removed, and depositing the membrane layer 101 over the first sacrificial material. Formation of the first cavity 109 using a sacrificial layer means that the etching of the substrate cavity 108 does not play any part in defining the diameter of the membrane. Instead, the diameter of the membrane is defined by the diameter of the first cavity 109 (which in turn is defined by the diameter of the first sacrificial layer) in combination with the diameter of the second cavity 110 (which in turn may be defined by the diameter of a second sacrificial layer). The diameter of the first cavity 109 formed using the first sacrificial layer can be controlled more accurately than the diameter of a back-etch process performed using a wet-etch or a dry-etch. Etching the substrate cavity 108 will therefore define an opening in the surface of the substrate underlying the membrane 101 .
[0008] A plurality of holes, hereinafter referred to as bleed holes 111 , connect the first cavity 109 and the second cavity 110 .
[0009] As mentioned the membrane may be formed by depositing at least one membrane layer 101 over a first sacrificial material. In this way the material of the membrane layer(s) may extend into the supporting structure, i.e. the side walls, supporting the membrane. The membrane and back-plate layer may be formed from substantially the same material as one another, for instance both the membrane and back-plate may be formed by depositing silicon nitride layers. The membrane layer may be dimensioned to have the required flexibility whereas the back-plate may be deposited to be a thicker and therefore more rigid structure. Additionally various other material layers could be used in forming the back-plate 104 to control the properties thereof. The use of a silicon nitride material system is advantageous in many ways, although other materials may be used, for instance MEMS transducers using polysilicon membranes are known.
[0010] In some applications, the microphone may be arranged in use such that incident sound is received via the back-plate. In such instances a further plurality of holes, hereinafter referred to as acoustic holes 112 , are arranged in the back-plate 104 so as to allow free movement of air molecules, such that the sound waves can enter the second cavity 110 . The first and second cavities 109 and 110 in association with the substrate cavity 108 allow the membrane 101 to move in response to the sound waves entering via the acoustic holes 112 in the back-plate 104 . In such instances the substrate cavity 108 is conventionally termed a “back volume”, and it may be substantially sealed.
[0011] In other applications, the microphone may be arranged so that sound may be received via the substrate cavity 108 in use. In such applications the back-plate 104 is typically still provided with a plurality of holes to allow air to freely move between the second cavity and a further volume above the back-plate.
[0012] It should also be noted that whilst FIG. 1 shows the back-plate 104 being supported on the opposite side of the membrane to the substrate 105 , arrangements are known where the back-plate 104 is formed closest to the substrate with the membrane layer 101 supported above it.
[0013] In use, in response to a sound wave corresponding to a pressure wave incident on the microphone, the membrane is deformed slightly from its equilibrium position. The distance between the lower electrode 102 and the upper electrode 103 is correspondingly altered, giving rise to a change in capacitance between the two electrodes that is subsequently detected by electronic circuitry (not shown). The bleed holes allow the pressure in the first and second cavities to equalise over a relatively long timescales (in acoustic frequency terms) which reduces the effect of low frequency pressure variations, e.g. arising from temperature variations and the like, but without impacting on sensitivity at the desired acoustic frequencies.
[0014] The transducer shown in FIG. 1 is illustrated with substantially vertical side walls supporting the membrane layer 101 in spaced relation from the back-plate 104 . Given the nature of the deposition process this can lead to a high stress concentration at the corners formed in the material layer that forms the membrane. Sloped or slanted side walls may be used to reduce the stress concentration. Additionally or alternatively it is known to include a number of support structures such as columns to help support the membrane in a way which reduces stress concentration. Such columns are formed by patterning the first sacrificial material used to define the first cavity 109 such that the substrate 105 is exposed in a number of areas before depositing the material forming the membrane layer 101 . However, this process can lead to dimples in the upper surface of the back-plate layer in the area of the columns.
[0015] It will be appreciated that, in order to incorporate the transducers into useful devices, it is necessary to interface or couple them to electronic circuitry.
[0016] As shown in FIG. 1 the membrane electrode 104 and back-plate electrode 108 are typically connected via tracks (not shown) to contact pads 116 and 118 respectively for connection to electronic circuitry. The tracks are formed during deposition and patterning of the relevant electrode and provide a connection from the electrode to a contact area a short distance away from the structure of the transducer. The conducting tracks are buried in subsequent deposition stages. Part of the fabrication process involves etching holes down to the end of the tracks and filling with conductive material to provide conductive vias. The top of the conductive vias are covered with the contact pads for connection to the electronic circuitry.
[0017] The circuitry may conveniently be CMOS (complementary-metal-oxide-on-semiconductor) circuitry and thus comprise various CMOS layers. As the skilled person will appreciate CMOS circuitry is formed by depositing appropriate metal and inter-metal dielectric (IMD) or inter layer dielectric (ILD) materials over appropriately doped regions of the substrate.
[0018] Commonly, MEMS capacitive transducers are fabricated on a separate substrate to the electronics. Thus the contact pads 116 and 118 described above with reference to FIG. 1 are arranged as, or are electrically connected to, bond pads suitable for wire bonding to corresponding bond pads on a separate substrate carrying the electronic circuitry.
[0019] More recently, efforts have been focussed on integrating the electronic circuitry and the transducer onto a single substrate, so that the MEMS structure and associated circuity, e.g. biasing circuitry and/or amplifier circuitry, are fabricated on the same chip. This can have a number of benefits and advantages. For example the integration of a MEMS transducer with electronic circuity on the same substrate provides a reduction in size compared to a two-chip design. It also avoids the need for connections such as bond pads and wire bonds in the signal path between the MEMs transducer and the circuitry, which can introduce unwanted parasitic capacitances and/or inductances and resulting signal loss.
[0020] The electronic circuitry associated with operation of the transducer, e.g. biasing circuitry and/or amplifier circuitry, will typically comprise a plurality of transistors and interconnections. This circuitry may be fabricated by using standard integrated circuit processing techniques, for instance CMOS processing.
[0021] As mentioned above, MEMS transducers are increasingly being used in portable devices with communication capability, e.g. mobile telephones or the like. Such devices will include at least one antenna for transmitting RF signals. The amount of power transmitted by such devices can be relatively high and is set to increase with changes to the communication standards. This can cause a problem for MEMS transducers, such as microphones, with CMOS circuitry. The transmitted RF signals can be coupled to the CMOS circuitry and, as the CMOS circuitry is inherently non-linear, such signals may be demodulated to the audio band. This may therefore result in audible noise such as the so-called “bumblebee noise”. This problem may be exacerbated when using MEMS microphones with integrated CMOS circuitry as in many devices the position of the antenna happens to be close to the position where the microphone is required.
[0022] It is known for electromagnetic shielding to be provided so as to protect a MEMS transducer and associated circuitry from electromagnetic radiation, in particular radio frequency interference (RFI). Such shielding is typically provided as part of the “package”, or cover, which protects and encloses the integrated MEMS transducer. For example, U.S. Pat. No. 7,166,910, U.S. Pat. No. 5,740,251 and U.S. Pat. No. 6,324,907 each disclose MEMS transducer assembly designs which incorporate conductive material as part of the lid, or package, so as to protect the enclosed transducer against electromagnetic interferences. In this sense, the package incorporating conductive shielding can act in the manner of a Faraday shield, to protect the transducer and associated circuitry against external electromagnetic (EM) interference.
[0023] A Faraday shield, or Faraday cage, utilises an electrically conductive material as a way of blocking, or attenuating, electromagnetic fields. A Faraday shield is commonly used to protect sensitive electronic components from external EM interference, in particular from external Radio Frequency Interference (RFI). As will be appreciated, the shielding effect of a conductive enclosure arises because an external electromagnetic field causes the electric charges within the cage's conducting material to be distributed such that they cancel the field's effect in the cage's interior. The energy caused by the EM radiation that is coupled into a Faraday cage is dissipated as eddy current losses.
[0024] Although the shielding provided by the previously considered designs is useful at attenuating external RF radiation, difficulties in protecting circuitry from RFI still arise. This is particularly a problem when the transducer package is located relatively close to an RF antenna within a communication device due to the strength of the RF field arising from the antenna which may be insufficiently attenuated by the previously considered shielding techniques.
SUMMARY
[0025] According to a first aspect of the present invention there is provided an integrated MEMS transducer comprising a MEMS transducer structure formed from a plurality of transducer layers and at least one circuit component formed from one or more circuitry layers, further comprising a conductive enclosure for attenuating electromagnetic radiation, wherein the conductive enclosure is formed from material comprised in a plurality of the transducer layers and/or the circuitry layers.
[0026] Thus, the conductive enclosure is formed of material that is deposited during the fabrication of the circuitry and/or during the fabrication of the MEMS transducer structure. As a result, the conductive enclosure forms an integral part of the integrated MEMS transducer. The conductive enclosure can be considered to be embedded within the structural layers of the integrated MEMS transducer.
[0027] According to a second aspect of the present invention there is provided an integrated MEMS transducer comprising a MEMS transducer structure formed from a plurality of transducer layers and at least one circuit component formed from one or more circuitry layers, further comprising a Faraday shield for attenuating RF radiation, the Faraday shield being formed of material comprised in one or more of the transducer layers.
[0028] Thus, the material that forms the eventual shield or enclosure will be deposited during the same processing steps that are carried out to form the integrated transducer. Thus, the conductive enclosure is efficiently fabricated in parallel to the fabrication of the circuitry layers and the transducer layers.
[0029] According to a further aspect of the present invention there is provided an integrated MEMS transducer comprising a MEMS transducer structure and at least one circuit component, the integrated MEMS transducer further comprising a conductive enclosure provided such that the at least one circuitry component is within the conductive enclosure, and wherein the MEMS transducer structure is outside the enclosure.
[0030] The MEMS transducer structure may be formed on a first region of a substrate and the at least one circuit component may be formed on a second region of the substrate. The circuitry may preferably comprise a plurality of CMOS layers. The CMOS layers typically comprise a plurality of dielectric layers and a plurality of metal layers. The transducer structure may be considered to comprise a plurality of transducer layers. Preferably, the transducer structure comprises a capacitive MEMS transducer comprising a moveable membrane having a membrane electrode and a back-plate having a back-plate electrode.
[0031] The conductive enclosure may comprise a top plate, formed of a metal/conductive layer, which overlies the circuitry or the first region of the substrate and acts in the manner of a Faraday shield to attenuate RF radiation. The top plate may be deposited during the deposition of one of the transducer layers, e.g. during the deposition of metal forming part of the transducer structure. The top plate may have a thickness that is greater than the thickness of one transducer layer e.g. the top plate be comprised of more than one layer of conductive material.
[0032] The conductive enclosure comprises a bottom plate that underlies the circuitry or the second region of the substrate. The bottom plate may comprise low resistance silicon, e.g. formed from a doped region of the silicon substrate, or a metal layer. Alternatively, the bottom plate may comprise an implant layer or a so-called “extra deep” implant layer formed e.g. by doping, within a deep well of the silicon substrate.
[0033] The conductive enclosure comprises at least one side wall which may be formed of a plurality of conductive vias which extend through one or more CMOS layers and serve to connect the top plate and the bottom plate. Thus, in a preferred embodiment the conductive enclosure comprises a top plate which overlies the circuitry and a bottom plate that underlies the circuitry, wherein the top plate and the bottom plate are connected by a plurality of conductive vias which extend through one or more layers of the integrated MEMS transducer to form side walls of the conductive enclosure and thereby to enclose the circuitry.
[0034] According to a further aspect of the present invention there is provided an integrated MEMS transducer comprising a MEMS transducer structure and circuitry provided on a single substrate/die, wherein the MEMS transducer is formed from a plurality of transducer layers and wherein at least one conductive layer deposited during the fabrication of the MEMS transducer structure forms a shield which overlies the circuitry for shielding the circuitry from electromagnetic radiation.
[0035] Preferably, the shield is electrically connected to a conductive layer which underlies the circuitry, thereby forming an electrically conductive enclosure around the circuitry.
[0036] The circuitry may comprise a plurality of CMOS layers and a plurality of conductive vias may be formed so as to extend through one or more CMOS layers from the underside of the shield to the underlying conductive layer, to form side walls of the conductive enclosure.
[0037] According to embodiments of the present invention the metal top plate may be formed during one or more of the metallisation steps carried out as part of the formation of the transducer structure.
[0038] According to a further aspect of the present invention there is provided an integrated MEMS transducer comprising, or incorporating, a conductive enclosure. Preferably, the conductive enclosure is formed from material comprised within the layers of the transducer structure and the circuitry structure (CMOS layers). Thus, the conductive enclosure is preferably formed from material deposited during the fabrication of the integrated MEMS transducer device.
[0039] According to a further aspect of the present invention there is provided an integrated MEMS transducer comprising a MEMS transducer structure formed of a plurality of transducer layers and at least one circuit component formed from a plurality of circuitry layers, wherein the integrated MEMS transducer further comprises a conductive enclosure that is integral to the transducer layers and circuitry layers. Preferably, the at least one circuit component is inside the conductive enclosure whilst the MEMS transducer structure is outside the enclosure.
[0040] According to a further aspect of the present invention there is provided an integrated MEMS transducer comprising a MEMS transducer structure formed from a plurality of transducer layers and at least one circuit component formed from one or more circuitry layers, further comprising a conductive enclosure which is embedded within the transducer layers and/or the circuitry layers so as to form an integral part of the integrate MEMS transducer.
[0041] According to a further aspect there is provided an integrated MEMS transducer comprising a MEMS transducer structure formed from a plurality of transducer layers and at least one circuit component formed from one or more circuitry layers, further comprising a Faraday shield for attenuating RF radiation, the Faraday shield being formed of material comprised in one or more of the transducer layers.
[0042] It will be appreciated that in the context of the present invention the term “walls” embraces not just a continuous plane of conductive material, but may also embrace a series of discrete columns or “castellation's”, which are preferably closely spaced. The present invention therefore conveniently provides a method that can be implemented using standard CMOS processing steps in a single standard CMOS foundry to produce an integrated transducer and electronics and further incorporating a shield or enclosure to protect the circuitry from RF radiation. Advantageously, all of the functional layers for the integrated MEMS transducer, including a conductive shield/enclosure for protecting the circuitry from RF radiation, can be fabricated as part of a CMOS process. This represents a more efficient solution from the perspective of manufacturing an integrated MEMS transducer, as compared to previously considered integrated transducer designs which incorporate conductive shielding material as part of the package or cover, since the fabrication of the enclosure/shield occurs in parallel with the fabrication of the device and results in electromagnetic shielding that is integral to the structure of the MEMS transducer and associated circuitry. In this sense, the protective Faraday shield/enclosure is formed during the wafer-level processing rather than at the package-level processing. This represents a more efficient and streamlined manner of fabricating a Faraday shield/enclosure to protect the circuitry components of an integrated MEMS transducer.
[0043] According to embodiments of the present invention the conductive enclosure forms a so-called Faraday cage. Due to the locality/proximity of the enclosure to the circuitry—in other words as a consequence of the shield/enclosure being an integral part of the integrated MEMS transducer which surrounds the circuitry components, it is possible to provide improved/greater attenuation of RFI. Thus, preferred embodiments of the present invention may protect the sensitive circuit components from external electromagnetic interference by attenuating electromagnetic radiation, even when the integrated transducer is to be located close to an antenna which acts as a source of RF radiation.
[0044] The transducer is a capacitive transducer and thus comprises a membrane electrode and a back-plate electrode. If a suitably conductive material is used for the membrane layer or back-plate layer then a single layer may provide the structure of the membrane/back-plate and also function as the electrode. Conveniently however there are a plurality of membrane layers, comprising at least one structural membrane layer and at least one membrane electrode layer, and a plurality of back-plate layers comprising at least one structural back-plate layer and at least one back-plate electrode layer.
[0045] The transducer is fabricated in a first area on the substrate and the at least one circuit component in a second area of the substrate. The transducer and the circuitry are thus formed at different parts of the substrate. Preferably the method involves forming the circuit layers, i.e. the at least one metal layer and the at least one dielectric layer, into a plurality of circuit components in the second area. The circuit components may be arranged to provide suitable circuitry for the MEMS transducer. Suitable circuitry may include, without limitation, amplifier circuitry, voltage biasing circuitry, filter circuitry, analogue to digital converters and/or digital to analogue converters, oscillator circuitry, voltage reference circuitry, current reference circuitry and charge pump circuitry.
[0046] The second area may be located in a distinct region of the substrate to the first region. For instance the transducer may be formed such that it is located on one side of the substrate and the circuitry may be located on the other side of the substrate. As used herein the term substrate is taken to refer to the final substrate of an individual device. The skilled person will appreciate that multiple devices are typically processed on a single wafer and ultimately diced into individual substrates.
[0047] According to a further aspect of the present invention there is provided a method of fabricating an integrated MEMS transducer comprising a MEMS transducer structure and at least one circuit component on a substrate, the method comprising: forming, on a first region of the substrate, a plurality of CMOS layers, wherein the at least one circuit component is formed from one or more of the CMOS layers; forming, on a second region of the substrate, a plurality of transducer layers to form the MEMS transducer structure; wherein said method comprises depositing a common layer of conductive material which forms a conductive layer of the MEMS transducer structure and also forms a top-plate which overlies the at least one circuit component, said top-plate being for shielding the circuitry from electromagnetic radiation.
[0048] In one embodiment, the method comprises the step of forming the dielectric and metal layers of the circuit layers prior to forming any of the transducer layers. The transducer layers are thus formed on top of the dielectric layers deposited in the first area during formation of the circuit layers. The transducer membrane is therefore arranged over a cavity formed in at least one of the CMOS layers. It will be clear therefore that the transducer in this embodiment is not fabricated directly on the surface of the substrate but on top of other layers deposited on the substrate. As used herein the step of forming a layer on the substrate includes forming such a layer on top of any intervening layers formed on the substrate.
[0049] The transducer may be a capacitive sensor such as a microphone. The transducer may comprise readout circuitry (analogue and/or digital). The transducer and circuitry may be provided together on a single semiconductor chip—e.g. an integrated microphone. Alternatively, the transducer may be on one chip and the circuitry may be provided on a second chip. The transducer may be located within a package having a sound port, i.e. an acoustic port. The transducer may be implemented in an electronic device which may be at least one of: a portable device; a battery powered device; an audio device; a computing device; a communications device; a personal media player; a mobile telephone; a tablet device; a games device; and a voice controlled device.
[0050] The MEMS capacitive transducers of the present invention may comprise sensing transducers such as a microphone and/or transmitting transducers such as loudspeakers. Where the apparatus comprises a plurality of transducers on the same substrate there may be one or transmitter and one or more receiver on the same substrate.
[0051] Features of any given aspect may be combined with the features of any other aspect and the various features described herein may be implemented in any combination in a given embodiment.
[0052] Associated methods of fabricating a MEMS transducer are provided for each of the above aspects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] For a better understanding of the present invention, and to show how the same may be carried into effect, reference will now be made by way of example to the accompanying drawings in which:
[0054] FIGS. 1 a and 1 b show a known capacitive MEMS transducer;
[0055] FIG. 2 shows an example cross section through some CMOS circuitry layers according to a typical CMOS process;
[0056] FIG. 3 illustrates an integrated MEMS transducer according to one embodiment of the present invention;
[0057] FIG. 4 illustrates a possible arrangement of conductive vias forming a side wall of a conductive enclosure according to an embodiment of the present invention; and
[0058] FIGS. 5 a , 5 b , and 5 c illustrate an integrated MEMS transducer according to another embodiment of the present invention and incorporating several alternative bottom plate designs.
DESCRIPTION
[0059] The examples described below will be described in relation to the integration of a MEMS microphone with CMOS circuitry. However, it will be appreciated that the general teaching applies to a variety of other MEMS transducers, including loudspeakers and pressure sensors as well as any other MEMS transducer incorporating at least one circuit component that is integrated on a single die.
[0060] FIG. 3 shows an integrated MEMS transducer generally indicated 200 comprising a capacitive MEMS transducer structure 300 , circuitry 400 and a conductive enclosure 500 . The transducer 300 comprises a moveable membrane 302 having a membrane electrode 303 and a backplate 304 having an embedded backplate electrode 305 . The transducer is formed in a first, transducer, region from a plurality of transducer layers or “MEMS” layers 301 . The circuitry 400 is formed in a second, circuitry region from a plurality of CMOS layers 401 which are formed by depositing appropriate metal and inter-metal dielectric or inter-layer dielectric materials. In this example, the transducer layers 301 are formed on top of the CMOS layers 401 . The circuitry and the MEMS transducer are provided on a substrate 402 . In this example the substrate 402 can be considered to form one of the CMOS layers.
[0061] Membrane electrode 303 is routed via one or more electrical interconnects (not shown) and input to one or more of the circuitry components (for example, as referenced “A” in FIG. 3 ). Backplate electrode 305 is also routed via one or more electrical interconnects (not shown) and input to one or more of the circuitry components (for example, as referenced “B” in FIG. 3 ). One of the circuitry components is also routed to an output (as referenced “C” in FIG. 3 ). The enclosure 500 , which acts as a Faraday cage for attenuating incident electromagnetic radiation, is preferably but not necessarily grounded (GND).
[0062] In this embodiment, the conductive enclosure 500 is formed from three key components, namely a conductive/metal top plate 501 (or “top”), a deep implant layer 502 (or “bottom”), and side walls 503 (or “side”), which connect the top plate 501 with the deep implant layer 502 to thereby provide a conductive enclosure around the circuitry. The top plate comprises a metal plate formed of at least one metal layer which is compatible with CMOS processing and which exhibits the required conductive properties for attenuating radiofrequency interference. For example, the top plate 501 may conveniently be formed of aluminium or copper.
[0063] In this example a deep implant layer forms a bottom plate 502 of the conductive enclosure 500 . The deep implant layer is provided within the silicon substrate 402 and is formed by known means.
[0064] The side walls 503 are preferably formed from conductive vias. The formation of vias through the circuitry layers is achieved by etching holes through the stack of the circuitry layers and then filling the holes with a conductive material. The vias may be continuous trenches which substantially form a complete side wall of the enclosure. Alternatively, the vias may be discrete, preferably closely spaced, elements, or “castelattions”. FIG. 4 shows a cross-sectional view through the circuitry layers 401 in order to illustrate an offset repeating pattern of the vias 504 which facilitates electrical interconnection of the layers. In effect, the side walls can be considered to be a cage within a cage.
[0065] During fabrication of an integrated MEMS transducer having a conductive enclosure according to embodiments of the present invention, a suitable bottom-plate is formed prior to the deposition of the circuitry and transducer layers. The bottom-plate is formed so as to extend beneath the intended circuitry components formed from the CMOS layers. A number of possible bottom-plate designs may be employed within the scope of embodiments of the present invention which will be discussed with reference to FIGS. 5 a to c.
[0066] Following the formation of the conductive back plate, the necessary CMOS circuitry is fabricated in the circuitry region using standard processing techniques that will be appreciated to those skilled in the art such as ion implantation, photomasking, metal deposition and etching. The circuitry may, without limitation, comprise some or all of amplifier circuitry, voltage biasing circuitry, filter circuitry, analogue to digital converters and/or digital to analogues converters, oscillator circuitry, voltage reference circuitry, current reference circuitry and charge pump circuitry. It will be appreciated that the circuitry layers will actually be varied across the circuitry region of the substrate to form distinct components and interconnections between components. The circuitry layers illustrated in FIG. 3 , and in all the present examples, are for illustration purposes only.
[0067] Following the fabrication of the CMOS circuitry, a plurality of conductive vias are formed which connect the bottom plate with the intended top plate. Thus, the conductive vias form the side walls of the eventual conductive enclosure.
[0068] Once the CMOS layers have been fabricated the transducer layers are fabricated using techniques that will be known to those skilled in the art. Briefly, the fabrication of the membrane involves fabricating a membrane layer 302 comprising silicon nitride which is deposited using plasma enhanced chemical vapour deposition process to a thickness of about 0.4 μm for example. A membrane electrode layer is also deposited and patterned to form membrane electrode 303 . The membrane electrode may comprise any suitable metal which is compatible with CMOS processing, such as aluminium, and may be deposited by sputtering. The thickness of the membrane electrode may be about 0.05 μm. Back plate layers are then deposited and may preferably comprise the same material as the membrane layer such as silicon nitride. Alternatively different materials may be used for one or more of the backplate layers if desired. The backplate electrode may be conveniently formed from the same metal as the membrane electrode, such as aluminium, and may be of the order of 1 μm thick.
[0069] According to embodiments of the present invention the metal top plate may be formed during one or more of the metallisation steps carried out as part of the formation of the transducer structure.
[0070] Thus, an advantage of embodiments of the present invention is that the enclosure 500 may be fabricated in parallel with the fabrication of the integrated MEMS transducer and circuitry using standard CMOS processing steps to form the elements of the enclosure. In other words, the production of the Faraday enclosure is merged with the production of the integrated MEMS transducer and may be conducted as a continuous process in a single standard CMOS foundry. Thus, the formation of the bottom-plate within, or on top of, the substrate is carried out prior to the deposition of the circuit layers. The via side walls are formed following the fabrication of the circuitry layers and prior to the formation of the transducer layers. Then, the metal top plate is formed, preferably by deposition, during the formation of the metal electrodes of the transducer layers. The method of the present invention therefore offers a truly CMOS process for the fabrication of integrated transducers incorporating a Faraday shield/enclosure.
[0071] FIGS. 5 a to 5 c show a cross section through an integrated MEMS transducer 600 formed on a silicon wafer 601 according to another embodiment of the present invention and illustrate three alternative bottom-plate designs. The MEMS transducer structure is generally designated 602 and includes a metal membrane electrode and a metal backplate electrode 603 a and 603 b . CMOS circuitry 610 is provided in a second, circuitry region, of the device. The circuitry is protected from EM interference by the provision of a conductive enclosure which is formed from a metal top-plate 604 , a plurality of conductive vias forming side walls 605 , and a bottom plate 606 which is configured to electrical connects the four side walls of the enclosure. In FIG. 5 a the bottom-plate is formed of a metallisation layer 606 that is formed within the silicon wafer. In FIG. 5 b the bottom-plate is formed of an extra-deep implant 607 that is formed within the silicon wafer. In FIG. 5 c the bottom-plate is formed of a region of low-resistance silicon that underlies the CMOS circuitry 610 . The top-plate 604 forms the top of the conductive enclosure and is comprised of a metalisation layer that is deposited during the deposition of metals layers required for the transducer structure—i.e. for the pair of electrodes and for providing an electrical connection between the transducer structure and the circuitry.
[0072] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. The word “comprising” does not exclude the presence of elements or steps other than those listed in a claim, “a” or “an” does not exclude a plurality, and a single feature or other unit may fulfil the functions of several units recited in the claims. Any reference signs in the claims shall not be construed so as to limit their scope. | The application relates to integrated MEMS transducers comprising a MEMS transducer structure formed of a plurality of transducer layers and at least one circuit component formed from a plurality of circuitry (CMOS) layers. The integrated MEMS transducer further comprises a conductive enclosure that is integral to the transducer layers and circuitry layers. The at least one circuit component is inside the conductive enclosure whilst the MEMS transducer structure is outside the enclosure. | 1 |
PRIORITY
[0001] This application claims the benefit of U.S. Provisional Application No. 61/903,583, filed Nov. 13, 2013, the entire content of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure generally relates to motors, motor controllers, systems and methods for controlling motors in various applications, and more particularly, to a motor connected to a pump having a dual speed pump controller for controlling the operation of recirculating pumps used in swimming pool environments.
BACKGROUND
[0003] Standard recirculating pumps having a motor section and a pump section are often used in swimming pool environments in connection with the filtering systems. The pumps are often high capacity pumps that move thousands of gallons per hour. The electric power required to move these large volumes of water is often very high and create high temperatures in the motor section.
[0004] Controllers for the pumps are often required to control the operation of the motor, for example, many federal and local governments have enacted laws and regulations to curtail the high electric use. Due to high temperatures in the end caps of the motor, controllers are usually remote from the motor and require extensive wiring connections between the controller and motor to control the motor operation. In addition, the controller will require a separate housing to protect the controller circuitry.
[0005] Attempts that have been made to design pumps to operate within temperature tolerances to prevent damage to the controllers contained in the motor section, none of which adequately address the problem at hand.
[0006] This disclosure describes improvements over these prior art technologies.
SUMMARY
[0007] Accordingly, an end cap for a motor housing containing an electric motor is disclosed The end cap assembly can include a tubular structure defining an interior space, which can include an open first end connectable to the motor casing; a second end, which can include a first planar surface; a second planar surface offset from the first planar surface and substantially parallel to the first planar surface; and at least one air grate surface substantially perpendicular to the first planar surface and the second planar surface, positioned between and attached to the first planar surface and the second planar surface, and wherein the at least one air grate surface includes at least one air grate configured to permit air flow into and/or out of the interior space.
[0008] In the end cap the at least one air grate surface can include two air grates each positioned substantially along a different radial line of the end cap.
[0009] In the end cap the air grate surface can be one of a planar surface or an arcuate surface,
[0010] The end cap can further include circuit board mountings positioned within the interior space configured to attach a circuit board thereto; and end cap mountings positioned to attach the end cap to the electric motor.
[0011] In the end cap the air grate surface can include at least two air grates positioned such that as the motor rotates a directional air flow is created within the interior space generating air flow through the air grates with one air grate as an intake air grate and the other grate as an exhaust air grate.
[0012] In the end cap the air grates can be each positioned substantially parallel to radial lines of the end cap.
[0013] In the end cap the air grate surface can define at least one switch receptacle configured to mount a control switch therein.
[0014] Accordingly, a motor assembly having a shaft end and a motor end is disclosed. The motor assembly can include an end cap removably connectable to the motor assembly at the motor end and defining a tubular space therein, which can include a first an open first end connectable to the motor end; a second end, which can include a first planar surface; a second planar surface offset from the first planar surface and substantially parallel to the first planar surface; and at least one air grate surface positioned between the first planar surface and the second planar surface and substantially perpendicular to the first planar surface and the second planar surface, the air grate surface including at least one air grate configured to permit air flow into and/or out of the interior space; and a motor control module having a substantially semi-circular design and configured to be mounted within the tubular space of the end cap and electrically connectable to the motor to provide control to the motor.
[0015] In the motor assembly the at least one air grate surface can include two air grates each positioned substantially along a different radial line of the end cap.
[0016] In the motor assembly the air grate surface can be one of a planar surface or an arcuate surface.
[0017] The motor assembly can further include circuit board mountings positioned within the interior space configured to attach a circuit board thereto; and end cap mountings positioned to attach the end cap to the electric motor.
[0018] In the motor assembly the air grate surface can include at least two air grates positioned such that as the motor rotates a directional air flow is created within the interior space generating air flow through the air grates with one air grate as an intake air grate and the other grate as an exhaust air grate.
[0019] In the motor assembly the air grates can be each positioned substantially parallel to radial lines of the end cap.
[0020] In the motor assembly the air grate surface can define at least one switch receptacle configured to mount a control switch therein.
[0021] Accordingly, disclosed is a control module for controlling a motor and mountable within an interior tubular cavity of a tubular end cap of a motor assembly. The control module can include a circuit board having a substantially semi-circular configuration with a diameter less than a diameter of the interior tubular cavity and mountable within the interior tubular cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The present disclosure will become more readily apparent from the specific description accompanied by the attached drawings, in which:
[0023] FIG. 1 is a side perspective view of a pump/motor assembly including a motor end cap according to the present disclosure;
[0024] FIG. 2 is a side perspective view of a pump/motor assembly including a partially-removed motor end cap according to the present disclosure;
[0025] FIG. 3 is a top perspective view of a motor end cap according to the present disclosure;
[0026] FIG. 4 is a top plan view of a motor end cap according to the present disclosure;
[0027] FIG. 5 is a side plan view of a motor end cap according to the present disclosure;
[0028] FIG. 6 is a bottom perspective view of a motor end cap according to the present disclosure;
[0029] FIG. 7 is a bottom plan view of a motor end cap according to the present disclosure;
[0030] FIG. 8 is a top plan view of a circuit board for use in a motor end cap according to the present disclosure; and
[0031] FIG. 9 is a bottom plan view of a motor end cap with a circuit board included therein according to the present disclosure;
[0032] FIG. 10 is a top perspective view of a motor end cap according to the present disclosure; and
[0033] FIG. 11 is a top perspective view of a motor end cap according to the present disclosure.
[0034] Like reference numerals indicate similar parts throughout the figures.
DETAILED DESCRIPTION
[0035] The present disclosure may be understood more readily by reference to the following detailed description of the disclosure taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure.
[0036] Also, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure.
[0037] Reference will now be made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying figures.
[0038] Controllers are often used to control the operation of a motor. The motors can operate various devices, for example, pumps, vehicles, cooling units, etc. One example of a pump/motor assembly having a controller is disclosed in U.S. application Ser. No. 14/536,929, filed Nov. 10, 2014, and entitled DUAL SPEED MOTOR CONTROLLER AND METHOD FOR OPERATION THEREOF, the entire contents of which are incorporated herein by reference.
[0039] A pump/motor assembly 10 according to the present disclosure includes a pump section 13 and a motor section 12 . Motor section 12 includes novel end cap 11 . Controller circuit board 80 (see FIG. 8 ) is designed to fit within motor end cap 11 as shown in FIG. 9 . End cap 11 is removable from motor section 12 to expose motor 21 contained within motor housing 22 . (See FIG. 2 ).
[0040] End cap 11 comprises a tubular body 31 , open at one end and closed at the other, The closed end includes a first planar surface 32 , a second planar surface 33 , and at least one air grate surface 34 . First planar surface 32 is substantially parallel to second planar surface 33 . The at least one air grate surface 34 is substantially perpendicular to and positioned between first and second planar surfaces 32 / 33 . The at least one air grate surface 34 includes an air grate 36 to permit airflow there through.
[0041] In an embodiment illustrated in FIG. 3 , five air grate surfaces 34 a - 34 e are shown, two of which, i.e. 34 b and 34 d, include air grates 36 i and 36 e, respectively. In another embodiment illustrated in FIG. 10 , one air grate surface 34 is shown, having a single air grate 36 . Other configurations varying the number of air grate surfaces 34 and air grates 36 are contemplated. For example, although air grate surface is shown as a planar surface, as shown in FIG. 11 the air grate surface can be configured as an arcuate surface having one or more air grates positioned thereon. Other configurations having a combination of planar and arcuate surfaces are also contemplated.
[0042] The embodiment of FIG. 3 shows a plurality of air grate surfaces connected in series, at least two of which include air grates positioned substantially opposite each other such that as the motor rotates a directional air flow is created in the interior space with one air grate being an intake air grate and the other grate being an exhaust air grate.
[0043] In operation, as the motor spins, air currents will be produced through air grates 36 . The air currents will flow into and out of the interior of end cap 11 . This continuous air flow will continuously cool the interior of end cap 11 and thus cool controller circuit board 80 , thus protecting controller circuit board 80 from overheating.
[0044] In a preferred embodiment and described with reference to FIG. 7 , planar surface 34 includes 2 air grate surfaces 34 b and 34 d each including an air grate 36 . The positioning of surfaces 34 b and 34 d are selected to maximize the air flow produced as an effect of the rotation of the motor. As motor rotates about axis z in direction A the rotation causes air flow within tubular body 31 in direction B. Intake air grate 36 i permits air flow into tubular body 31 in direction C and exhaust air grate 36 e permits air flow out of tubular body 31 in direction D. Angles α and β are selected to maximize the air flow and can change based on the position of the planar surfaces 34 b and 34 d. Air flow can be maximized when an air grate is substantially perpendicular to the air flow at the position of the air grate. In other words, air grates positioned substantially along radial lines of the end cap can maximize the air flow. In addition, although the configuration shown is substantially symmetrical about a line between the 2 air grates, other non-symmetrical designs are contemplated.
[0045] In the embodiment of FIG. 10 , the air flow can be further maximized if the single planar surface 34 is provided with 2 air grates spaced apart from each other and the planar surface is positioned substantially on a diameter line of the end cap. This will position the air grates substantially perpendicular to the direction of the air flow at the each air grate.
[0046] Also shown in FIG. 3 is optional switch cut-out 37 positioned within one of the at least one air grate surfaces 34 into which a switch (not shown) can be mounted to provide input to the controller circuit board 80 as described in U.S. application Ser. No. 14/536,929. Also includes are screw receptacles 35 to receive a screw to attach end cap 11 to motor housing 22 and/or motor 21 . End cap 11 can also include a power cord access 38 to permit connection of electric power to the electrical components of the pump/motor assembly 10 .
[0047] The interior of end cap 11 is mostly hollow and designed to accept controller circuit board 80 . For example, a typical inside diameter of an end cap might be 5½ inches in diameter. If so, end cap 11 would have that same inside diameter. Controller circuit board 80 is specially designed as a semi-circle having a diameter of 5¼ inches to fit within the interior of end cap 11 (see FIG. 6 ) as shown in FIG. 9 .
[0048] The present disclosure has been described herein in connection with a pump/motor assembly in a swimming pool environment, but is applicable to any electric motor that requires cooling in its end cap. Other applications are contemplated.
[0049] Where this application has listed the steps of a method or procedure in a specific order, it may be possible or even expedient in certain circumstances, to change the order in which some steps, are performed, and it is intended that the particular steps of the method or procedure claim set forth herebelow not be construed as being order-specific unless, such order specificity is expressly stated in the claim.
[0050] While the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Modification or combinations of the above-described assemblies, other embodiments, configurations, and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the art are intended to be within the scope of the claims. | Disclosed is an end cap for a motor housing containing an electric motor, including a tubular structure defining an interior space, including an open first end connectable to the mater casing; a second end, including a first planar surface; a second planar surface offset from the first planar surface and substantially parallel to the first planar surface; and at least one air grate surface substantially perpendicular to the first planar surface and the second planar surface, positioned between and attached to the first planar surface and the second planar surface, and wherein the at least one air grate surface includes at least one air grate configured to permit air flow into and/or out of the interior space. | 5 |
BACKGROUND OF THE INVENTION
This invention relates generally to self-propelled vehicles having dual wheel pairs on at least one axle and particularly to small pickup truck and camper vehicles in which the storage of multiple spare wheels is difficult.
It is often found desirable by truck and camper vehicle users to utilize a dual wheel configuration on the rear drive axle of the vehicle. Such dual wheel configurations are well known in the art and, as the name indicates, comprise an axle combination in which a pair of closely spaced wheels are positioned at each end of the axle combination. Generally, all four wheels on the dual wheel axle are directly driven by the axle structure. As a result, increased load bearing capability is provided since all four wheels share the load previously distributed to two wheels. Further, because the traction surface of the dual wheel pair is approximately twice that of the single wheel pair, increased traction is also obtained. In addition, it is often considered aesthetically desirable among truck and camper enthusiasts to provide such dual wheel pairs.
For these reasons, the majority of truck and camper manufacturers make available an option permitting the customer, at the time of purchase, to select the dual wheel configuration. When so provided, these vehicles are available with a standard single wheel configuration on the front two wheels of the vehicle and a four wheel dual pair arrangement on the rear. Because the wheel structure of the wheels used in dual wheel configurations differs from the wheel structure of the wheels used on the front single wheel configuration, the front and rear wheels are not interchangeable. Among other consequences of this difference in wheel construction is the resulting need for individual spare tires and wheels for the front and rear axles.
While such originally manufactured versions having factory installed dual wheel configurations do provide the increased load-bearing, traction and aesthetic accommodations set forth above, they are subject to several limitations. For example, as set forth above, such vehicles must be earmarked for dual wheel construction during the manufacturing process. Because of the general construction techniques of vehicles, it is generally not feasible to convert such systems subsequent to manufacture. Notwithstanding the expense and difficulty of such subsequent conversion, there remains in addition lack of the interchangeability between front and rear wheel hubs creating the above-mentioned need for two spare wheels. While the accommodation of a second spare wheel is of some PG,4 difficulty in larger trucks and camper vehicles, it is often prohibitive for small trucks and campers due to the limited space available.
In view of the foregoing, it is clear, therefore, that there remains a need in the art for a ready means of converting a standard single wheel truck or camper to a dual wheel vehicle with a minimum of work and cost and without creating the need for carrying a second spare wheel.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide an improved dual wheel configuration for truck and camper vehicles. It is a more particular object of the present invention to provide an improved dual wheel configuration for truck or camper vehicles which may be installed without excessive expense subsequent to manufacture and which does not create the necessity of carrying a second spare wheel.
The present invention is for a wheel and hub adapter for use in combination with motor vehicles having drum or hub assemblies which include a generally flat mounting plate and a circular arrangement of wheel studs extending outwardly therefrom which are concentrically spaced from the center line of the vehicle axle and adapted to receive a wheel having an arrangement of apertures spaced in accordance with the wheel studs. The wheel includes a circular outer rim configured to receive a vehicle tire and a mounting surface coupled to the outer rim in an offset manner by a wheel web. The mounting surface of the wheel defines a center aperture concentric with the outer rim and a plurality of apertures arranged about the center aperture. The plurality of apertures is positioned about a circle concentric with the center aperture. A hub adapter is positioned between the drum assembly and the wheel and has a generally cylindrical wall portion terminating at one end in a planar surface having a plurality of apertures spaced from the center of the cylindrical surface on a uniform radius and adapted to receive the mounting studs of the vehicle drum assembly. The other end of the hub adapter has an alignment surface concentric with the axis of the cylindrical wall portion said alignment surface having a predetermined diameter. The hub adapter further has a wheel flange, spaced from the alignment surface by a uniform distance, extending outwardly therefrom, and has a second plurality of apertures uniformly spaced from the alignment surface on a circle concentric with the alignment surface whereby the adapter hub is secured to the vehicle drum and one or two wheels may be secured to the adapter flange. In the event a second wheel is used, its orientation is reversed from that of the first wheel and secured to the same flange.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The invention together with further objects and advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying in the several figures of which like reference numerals identify like elements and in which:
FIG. 1 is a perspective of a motor vehicle having a dual wheel configuration in accordance with the present invention;
FIG. 2 is a section view along the section lines 2--2 of FIG. 1;
FIG. 3 is a partial section view of the mounting detail of the adapter and wheel of FIG. 2;
FIG. 4 is a partial section view taken along section lines 4--4 of FIG. 1;
FIG. 5 is a plan view of the adapter hub of the present invention with the wheel removed; and
FIG. 6 is a perspective exploded view of the present invention adapter hub and the vehicle drum.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a pickup truck vehicle generally described by reference numeral 10 having a body 11 and supporting a front wheel 12, a second front wheel, (not visible), a bed 18, used generally to transport cargo, a bumper 17 and a plurality of windows 19. In accordance with the present invention, vehicle 10 further includes an outer rear wheel 13 and inner rear wheel 14 and inner rear wheel 15 and an outer rear wheel 16. Rear wheels 13 through 16 comprise a dual wheel combination constructed in accordance with the present invention. As can be seen, wheels 13 and 14, and 15 and 16, respectively, are paired at opposite ends of the axle configuration (not shown) of truck 10. With reference to FIG. 1 and as will be more clear in the accompanying descriptions below in connection with subsequent figures, front wheel 12 and outer rear wheels 13 and 16 are reversed with respect to the mounting surface of vehicle 10.
The rear wheels 13, 14, 15 and 16 provide the above described advantages of a dual wheel configuration while front wheel 12 and the corresponding but not visible other front wheel of the vehicle 10 are mounted in accordance with the present invention system to position the front wheels relative to the vehicle in accordance with the standard single wheel mount of the vehicle.
With reference to FIG. 2, the present invention wheel and adapter are shown in greater detail. A brake drum 20 which is of standard vehicle construction, defines a drum extension 23 which in turn defines a substantially planar hub mating surface 24 and a plurality of outwardly extending wheel studs 21. The latter extend away from hub mating surface 24 and are perpendicular thereto and, as is better shown in FIG. 6, are equally spaced about a bolt circle which is concentric with the center line of drum 20. It should be apparent to those skilled in the art that drum 20 can be replaced by the rotor assembly of a disc brake without departing from the scope of the present invention. An adapter 50 is constructed in accordance with the present invention and defines a cylindrical extension wall 51 which in turn defines an outer surface 53 and an inner surface 52 and an inwardly extending stud flange 55. The latter defines a drum mating surface 62, a central clearance aperture 59 and a plurality of stud apertures 56. Apertures 56 are concentrically spaced about the center line of adapter 50 such that the center line of adapter 50 is aligned with the center of brake drum 20 and drum extension 23 and in a manner corresponding to the spacing between wheel studs 21 of drum extension 23. Stud apertures 56 further define chamfers 57 which extend away from drum mating surface 62. A plurality of lug nuts 22 are internally threaded in accordance with standard construction and define conical surfaces 58 having a slope corresponding to chamfer 57. In accordance with conventional assembly practices, lug nuts 22 are threaded upon wheel studs 21 and tightened to a specified torque impressing conical surfaces 58 against chamfers 57 and maintaining adapter 50 against drum extension 23. As will be apparent to those skilled in the art, the combination of chamfers 57 and conical surfaces 58 in the foregoing prevent lug nut loosening and assure that the alignment of adapter 50 with respect to drum extension 23 is correct and repeatable during removal and mounting of adapter 50. The importance of this will be discussed below in greater detail. However, suffice it to say here that adapter 50 may as a result be repeatedly removed and mounted to drum extension 23 with assurance that each mounting will result in centering adapter 50 with respect to the center line of drum extension 23.
Adapter 50 further defines an alignment surface 54 at the end of adapter 50 most remote from stud flange 55 which is formed in a precision manner to insure that alignment surface 54 is concentric with the bolt circle of wheel studs 21. Adapter 50 further defines an outwardly extending wheel flange 31 which is attached to and extends orthogonally away from outer surface 53 and alignment surface 54. Wheel flange 31 further includes a plurality of apertures 32 which are spaced equally about wheel flange 31 and are located in a circular arrangement which is concentric with the alignment surface 54. A plurality of adapter bolts 29 extend through apertures 32 and are received by a plurality of adapter nuts 30. Adapter nuts 30 are of similar construction to lug nuts 22 and define conical surfaces 76. Adapter bolts 29 may be of standard construction and freely fit within apertures 32 or in the alternative may be press fitted into apertures 32 in a manner similar to that used in motor vehicle construction.
Front wheel 12 further includes a wheel rim generally described by reference numeral 25 which supports tire 40. Wheel rim 25 further includes a bead side wall portion 64 and a bead seat 43. Tire 40 includes a tire side wall 41 and a tire bead 42 and in accordance with typical motor vehicle tire mounting practices, tire 40 is maintained upon wheel rim 25 by the seal created between tire bead 42 and bead seat 43. Again, in accordance with commonly used motor vehicle tire mounting practice, tire 40 is inflated to a suitable pressure and the seal between tire bead 42 and bead seat 43 creates a force against the interior of tire side wall 41 and tire bead 42 urging tire bead 42 against bead side wall 64. Wheel 12 further includes a wheel web 26 of generally cone shaped configuration which is attached to wheel rim 25 by a weld seam 33 and which defines a plurality of cooling apertures 65. Wheel web 26 further defines a centering aperture 60 which, in accordance with an important aspect of the present invention, is concentric with wheel rim 25 and carefully sized to fit about alignment surface 54 of adapter 50 with a minimum of clearance. Wheel web 26 also defines a plurality of bolt apertures 28 spaced at uniform distances from centering aperture 60 and located in correspondence to the spacing of adapter bolts 29. Bolt apertures 28 further define chamfers 68 the importance of which will be described below in detail. Wheel web 26 also defines a flange mating surface 61 which is generally perpendicular to the center line of centering aperture 60 and which extends outwardly from centering aperture 60 beyond wheel mating surface 27 of wheel flange 31.
In accordance with the present invention, wheel 12 is mounted to adapter 50 by sliding centering aperture 60 over alignment surface 54 until flange mating surface 61 of web 26 contacts wheel mating surface 27 of flange 31. Thereafter, adapter nuts 30 and adapter bolts 29 are threaded together with adapter bolts 29 extending through apertures 32 and bolt apertures 28. Adapter nuts 30 are torqued to a specified tightness in which conical surfaces 76 are pressed into bolt apertures 28 pressing flange mating surface 61 and wheel mating surface 27 together.
FIG. 3 sets forth the alignment aspects of the present invention wheel and hub configuration in greater detail. FIG. 3 shows a portion of wheel flange 31 which, as mentioned, defines a wheel mating surface 27. Also shown is a portion of extension wall 51 of adapter 50 which defines alignment surface 54. Flange 31 is perpendicular to alignment surface 54 and is attached to adapter 50 by a welded seam 63. Also shown in FIG. 3 is a portion of wheel web 26 which, as mentioned, defines a generally flat flange mating surface 61 and a centering aperture 60. Because the diameter of centering aperture 60 is carefully controlled, a minimum clearance between centering aperture 60 and alignment surface 54 when wheel 12 is mounted to adapter 50 is achieved. In accordance with an important aspect of the present invention, the close tolerances of size and concentricity maintained between centering aperture 60 and alignment surface 54 are the dominant locating and centering mechanism for the present invention wheel and hub combination. With the relative diameters of centering aperture 60 and alignment surface 54 maintained, the centering of wheel 12 upon adapter 50 and therefore brake drum 20 is assured and the combination of adapter bolts 29, adapter nuts 30 and apertures 32 and 28 need only maintain a compressive force upon wheel flange 31 and wheel web 26 to complete the positive mounting of wheel 12 upon adapter 50. As will be described below in greater detail but which bears mention at this point, in accordance with an important aspect of the present invention, those skilled in the art will observe that the proper centering of wheel 12 with respect to adapter 50 is maintained regardless of whether wheel 12 is mounted to adapter 50 in the front single wheel configuration shown in FIG. 2 or the reverse position occupied by outer rear wheel 13 in FIG. 4. This important result flows from the fact that the centering of wheel 12 upon adapter 50 results from the close tolerances between centering aperture 60 and wheel alignment surface 54. In other words, wheel centering is virtually independent of the relationships between adapter bolts 29, adapter nuts 30 and apertures 32 and 28.
Returning to FIG. 2, it will be apparent to those skilled in the art that the incline of web 26 and the offset relationship between flange mounting surface 61 and wheel rim 25 is selected in accordance with the spacing between stud flange 55 and wheel flange 31 of adapter 50. In other words, the plane of tire 40 and wheel rim 25 is located or positioned with respect to hub mating surface 24 of drum extension 23 to maintain the same relationship between tire 40 and brake drum 20 achieved when tire 40 was supported by a conventional wheel upon brake drum 20.
FIG. 4 shows the mounting details of a dual wheel combination of inner wheel 14 and outer rear wheel 13. For purposes of clarity of explanation, the brake drum and adapter shown in FIG. 4 are assumed to be of the same construction as that used in the front wheel combination shown in FIG. 2. Accordingly, brake drum 20, drum extension 23 and adapter 50 as well as the details thereof retain the same reference numbers as those of adapter 50 and brake drum 20 in FIG. 2.
Because inner rear wheel 14 is constructed and mounted upon adapter 50 in the same manner as that set forth above for front wheel 12 described in connection with FIG. 2, the same reference numerals are used in FIG. 4 to identify the corresponding structural features of inner rear wheel 14 as are used for front wheel 12. Accordingly, reference should be taken to the descriptions above for the details of structure and mounting of inner rear wheel 14.
Outer rear wheel 13 is identical to both front wheel 12 and inner rear wheel 14 and includes a wheel rim 75 which supports a conventional tire in the manner set forth above for tire 40 upon front wheel 12. Outer rear wheel 13 further defines a wheel web 70 having an identical construction to wheel web 26 which is welded to wheel rim 75 along welded seam 78 and which defines a flange mounting surface 79 which in turn defines a plurality of bolt apertures 74. The latter define a chamfers 69, the importance of which will be described below in detail. Wheel web 70 further defines a centering aperture 71 which corresponds to centering aperture 60 of wheel web 26. As will be apparent to those skilled in the art by examination of FIG. 4, outer rear wheel 13 is positioned upon adapter 50 in the reverse relationship to that which exists between inner rear wheel 14 and adapter 50.
In accordance with the present invention, the dual wheel configuration shown is achieved by initially sliding inner rear wheel 14 upon adapter 50 such that alignment surface 54 passes through centering aperture 60 and wheel mating surface 27 of wheel flange 31 and flange mating surface 61 of wheel web 26 are brought into contact. Thereafter, outer rear wheel 13 is mounted to adapter 50 in the reverse position shown by sliding center aperture 71 over alignment surface 54 until inner wheel surfaces 72 and 73 of wheel webs 26 and 70 respectively are brought into contact. Adapter nuts 30 are then threaded upon adapter bolts 29 until conical surfaces 76 of adapter nuts 30 contact chamfers 69 of bolt apertures 74. Adapter nuts 30 are then tightened to the appropriate torque specification to maintain wheel flange 31 and wheel webs 26 and 70 in compression.
As will also be apparent to those skilled in the art, the cooperation of centering apertures 60 and 71 and alignment surface 54 of adapter 50 maintain both inner rear wheel 14 and outer rear wheel 13 in a properly centered alignment with respect to adapter 50 and brake drum 20 of the vehicle. In accordance with an important aspect of the present invention, and because outer rear wheel 13, inner rear wheel 14 and front wheel 12 are commonly structured, that is have structures and shapes which are identical, the respective wheels on both the single wheel configuration in the front of vehicle 10 and those on the dual wheel configuration in the rear are completely interchangeable. Therefore, a single spare wheel constructed in accordance with the structure of wheels 12 through 16 may be used anywhere on truck 10 in either the dual or single wheel arrangements of the vehicle. As a result, a single spare wheel may be used notwithstanding the dual wheel configuration of the vehicle. It will also be apparent to those skilled in the art that the dual wheel combination of vehicle 10 may be easily returned to a single wheel configuration by the simple removal of outer rear wheels 13 and 16 leaving vehicle 10 with a conventional four wheel arrangement.
Turning to FIG. 5, the details of adapter 50 may be examined with particular attention to the concentric relationships described above. As can be seen, wheel flange 31 is of circular configuration and accommodates the plurality of apertures 32 in an equally spaced relationship about hole circle 66. As discussed above, apertures 32 are equally spaced from alignment surface 54. Alignment surface 54 and inner surface 52 of extension wall 51 are, of course, also of circular configuration. In addition, stud flange 55 extends inwardly from inner surface 52 and terminates in a circular clearance aperture 59. Stud apertures 56 are equally spaced upon stud flange 55 about hole circle 57. As discussed above, hole circles 66 and 67 are concentric with alignment surface 54 to maintain the proper alignment between the wheel (or wheels if a dual wheel is used) mounted to adapter 50 and the brake drum of the vehicle.
Turning to FIG. 6 which sets forth in a partial exploded view of the relationship between adapter 50 and brake drum 20 of vehicle 10, it is shown that adapter 50 is mated to hub mounting surface 24 of drum extension 23 by sliding stud apertures 56 over wheel studs 21. Thereafter, lug nut 22 is placed upon each of wheel studs 21 in the manner described above. In the embodiment shown in FIG. 6, apertures 32 do not support adapter bolts 29. As mentioned above, there are alternative configurations by which adapter bolts 29 may be passed through apertures 32 of adapter 50 without departing from the spirit and scope of the present invention. In the anticipated embodiment shown, adapter bolts 29 each define knurled portions 80 interposed between threads 82 and heads 81, the size of which is selected with respect to aperture 32 to provide a press, or interference, fit therebetween. Accordingly, in this embodiment, adapter bolt 29 is maintained within aperture 32 of flange 31. In an alternative embodiment (not shown), adapter bolt 29 has a conventional smooth shank instead of knurl 80 and is fitted within aperture 32 in a conventional manner. In the latter case, however, care is nonetheless required to properly select the size of aperture 32 with respect to the shank of adapter bolt 29 to maintain clearances therebetween at a minimum.
Examination of the foregoing inventive structure reveals several advantages over conventional wheel structures. For example, it should be noted that a single uniform wheel construction may be employed in which all wheels are interchangeable upon the vehicle. In accordance with this important advantage, a single spare wheel is able to fit both single and dual wheel configurations and front and rear axles. In addition, the common wheel construction permits ready conversions between single and dual wheel configurations on the vehicle by the simple removal of the outer ones of the rear wheel pairs. Further, it will also be apparent that a common wheel structure may be utilized on a plurality of vehicle types provided that a corresponding adapter may be configured to receive the common wheel on the various types of vehicles. In other words, a single wheel structure may be used with several types of vehicles and an adapter particular to the differences between vehicles may be used to accommodate these changes. This is extremely advantageous over the alternative of having different wheel constructions for each of the different types of vehicles. Finally, it will be apparent that the present invention system is totally compatible with the standard manufacture of motor vehicles and that no modification to the existing motor vehicle need be made to convert such vehicle to the present invention wheel and hub structure apart from the removal of the existing wheels from the vehicle.
Accordingly, what has been shown and described herein is an improved wheel and adapter hub combination which may be used to convert a standard single wheel motor vehicle to a dual wheel construction without the necessity of additional spare wheels or modification of the vehicle itself.
The present embodiments of this invention are thus to be considered in all respects as illustrative and not restrictive; the scope of the invention being indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | A wheel and hub adapter provides the use of a common wheel structure in either single or dual wheel configurations for a camper, truck or the like. The wheel is reversible for front and rear axle use and includes a large precision sized center aperture with a surrounding plurality of smaller apertures. The hub adapter defines a cylindrical body having an inwardly extending flange which attaches to the conventional wheel studs of the vehicle and an alignment surface on the other end precision fitted to the center aperture of the wheel. A second flange extends outwardly from the adapter body near the precision alignment surface and receives a plurality of fasteners which secure the wheel to the flange. The center aperture and alignment surface cooperate to center the wheel or wheels with respect to the drum. | 1 |
[0001] This application claims priority from U.S. Provisional Patent Application Number 60/231,577, filed Sep. 11, 2000 and entitled “Optical Add/Drop Multiplexer and In-Band Wavelength Conversion”.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a method and apparatus for adding and dropping channels in an optical communications system.
[0004] 2. Description of Related Art and General Background
[0005] In many applications of dense-wavelength division multiplexed (DWDM) optical systems (for example, optical computer networks, CATV (cable television) systems, and telecommunications networks), there exists a need to allow local dropping and adding of traffic carried by one or more wavelengths. Applications include when optical channels are sent to or dropped from an optical transmission line e.g., for sending optical channels to a local bus or for adding local channels to an incoming data signal. This form of optical routing may be generally referred to as “add-drop multiplexing.”
[0006] While a basic optical add/drop multiplexer has been described by Taga, et al. (U.S. Pat. No. 5,822,095), it is suited to relatively wide channel spacing and is not suited to modern DWDM systems which tend to have a larger number of more narrow channels which are closely spaced. Mizrahi (U.S. Pat. No. 5,982,518) has proposed one solution for more narrow channels using sequential fiber gratings between optical circulators. In each case, however, a set of local transmitters is required to produce the added channels, increasing the cost and complexity of the add/drop node.
[0007] In each of these devices, each transmitter requires the use of a wavelength locker in order to maintain the wavelength stability of the transmitted channels. Such wavelength lockers are available which allow wavelength stability of between about 2.5 GHz and 5 GHz. However, such tolerances are only effective for use in networks having a channel spacing of about 50 GHz. When channel spacing is below about 10 GHz, currently available wavelength lockers are too imprecise to allow transmission without any interference between channels.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention address the needs identified above and others by providing a method of optical data transmission including receiving an optical signal having a plurality of components, each component having a different wavelength, receiving an information signal, separating a first one of the components from the optical signal, dropping a second one of the components from the optical signal, modulating the first one of the components with the information signal to obtain a modulated component, and combining the modulated component with the optical signal.
[0009] Another embodiment of the present includes an add/drop device for optical data transmission including an optical waveguide configured and arranged to receive a signal having a plurality of components, each component having a different wavelength, a splitter coupled to the optical waveguide and configured and arranged to produce a first output signal and a second output signal, each output signal having the plurality of components, a first filter configured and arranged to separate a first one of the components from the first output signal, a modulator configured and arranged to modulate the first component with an information signal, a second filter configured and arranged to drop a second one of the components, different from the first component, and a combiner configured and arranged to combine the modulated first component with the filtered second output signal.
[0010] Yet another embodiment of the present invention includes a dense wavelength division multiplexed optical transmission system, including a transmitter, an optical waveguide configured and arranged to receive an optical signal from the transmitter through the transmission line, the signal having a plurality of components, each component having a different wavelength, a splitter coupled to the optical waveguide and configured and arranged to produce a first output signal and a second output signal, each output signal having the plurality of components, a first filter configured and arranged to separate a first one of the components from the first output signal, a modulator configured and arranged to modulate the first component with an information signal, a second filter configured and arranged to drop a second one of the components, different from the first component, a combiner configured and arranged to combine the modulated first component with the filtered second output signal, and a receiver in optical communication with the combiner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification illustrate an embodiment of the invention and together with the description, explains the objects, advantages, and principles of the invention.
[0012] [0012]FIG. 1 is a schematic diagram illustrating an optical add/drop according to an embodiment of the present invention.
[0013] [0013]FIG. 2 schematically illustrates a broad band optical signal.
[0014] [0014]FIGS. 3 a and 3 b schematically illustrate a single band of an optical signal.
[0015] [0015]FIG. 4 schematically illustrates a broad band optical signal.
[0016] [0016]FIG. 5 is a schematic diagram illustrating an optical add/drop according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] In the following description, for purposes of explanation and not limitation, specific details are set forth such as particular optical and electrical circuits, circuit components, techniques, etc. in order to provide a thorough understanding of the present invention. However, the invention may be practiced in other embodiments that depart from these specific details. In some instances, detailed descriptions of well-known devices and circuits may be omitted so as not to obscure the descriptions of the embodiments of the present invention with unnecessary details.
[0018] Certain aspects of the description make mention of use of optical single sideband (OSSB) modulation or double sideband modulation. One method of optical single sideband transmission is disclosed in U.S. patent application Ser. No. 09/575,811 of Way et al., filed May 22, 2000, entitled “Method and Apparatus for Interleaved Optical Single Sideband Modulation”, and herein incorporated by reference. Other methods of optical single and double sideband modulation may be employed as appropriate.
[0019] For purposes of this specification, some channels will be referred to as having a characteristic wavelength or frequency. This does not mean that the channel is restricted to the exact recited wavelength or frequency. If the channel has a width, then the characteristic wavelength or frequency is taken to be at approximately the center of the width. If a channel is substantially monochromatic, then the characteristic wavelength or frequency will be the wavelength or frequency of the monochromatic light source.
[0020] An add/drop node 100 according to an embodiment of the present invention is shown in FIG. 1. The node 100 has an input 102 which is in optical communication with an optical path 104 . The optical path 104 , in most cases, will be a single mode fiber forming a part of an optical communication system. A transmitter 106 is in optical communication with the optical path 104 .
[0021] The input 102 may include an optical amplifier 108 , such as a erbium doped fiber amplifier. Likewise, the amplifier 108 may be disposed along the optical path 104 , or in both locations. An optical pre-filter 110 is in optical communication with the input 102 . The optical pre-filter 110 may be, for example, a fixed or tunable filter and may have a bandwidth approximately equal to the bandwidth of a single ITU-grid window, for example, about 25-60 GHz. An optical circulator 112 in communication with the optical pre-filter 110 provides a first optical path leading to an optical filter 114 . The optical filter 114 may be, for example, a tunable Fabry-Perot filter or a fiber grating based filter. An optical isolator 116 and a polarization controller 118 are disposed in the optical path between the optical filter 114 and a modulator 120 . The modulator 120 may be, for example, an optical double sideband modulator, an optical single sideband modulator or an interleaved optical single sideband modulator. Note that the polarization controller 118 is of particular import only for those embodiments of the add/drop node 100 including a polarization dependent modulator 120 , such as a Mach-Zehnder modulator. The modulator is in communication with a source 121 of an information signal to be added to the optical signal.
[0022] An output optical path 122 proceeds from the modulator 120 and may contain an optical amplifier 124 . A combiner 126 is disposed along the output optical path 122 . The combiner 126 may be any type of junction allowing optical signals from two fibers to be mixed, for example, the combiner 126 may be a 2×1 connector or a multiplexer.
[0023] A second optical path leading from the circulator 112 contains a filter 130 , such as a notch filter. The filter 130 may be, for example, a band reject filter, or a pair of cascaded band reject filters, providing a deeper, narrower notch. A second circulator 132 is in optical communication with the filter 130 and is in optical communication with an optical filter 134 . An additional optical filter 136 is in optical communication with the optical filter 134 and the two are separated by an optical isolator 138 . The two optical filters 134 , 136 may be, for example, tunable optical band pass filters. A photodetector 140 is optionally disposed in optical communication with the optical filters 134 , 136 . If there is no need to detect a signal passed by the filters 134 , 136 , a termination may be substituted for the photodetector 140 . The circulator 132 is further in optical communication with the optical output path 122 .
[0024] As may be seen in FIG. 2, the optical filter 134 may have a characteristic which results in a phenomenon of repeated passbands 142 . Since it is undesirable to drop channels at upper or lower repeated passbands in an uncontrolled way, the optical pre-filter 110 is used to remove bands outside of the band to be processed in the add/drop node 100 . Thus, it is preferable to set the bandwidth of the optical pre-filter 110 to be less than the free spectral range 150 of the optical filter 134 . As a matter of convenience, the bandwidth of the optical pre-filter may be selected to be about equal to the ITU window passband of a conventional DWDM multiplexer/demultiplexer.
[0025] In operation, the add/drop node 100 receives a signal including a plurality of channels λ 1 . . . λ n . The signal may be of a bandwidth greater than a single ITU-grid window as shown in FIG. 2. The signal includes an unmodulated carrier 200 as seen in FIGS. 3 a, 3 b and 4 .
[0026] [0026]FIG. 3 a shows one band B of an interleaved optical single sideband signal in which upper sideband channels 204 , 206 and lower sideband channels 208 , 210 are interleaved. That is, an upper sideband channel 204 differs in wavelength from the carrier by a different amount than both lower sideband channels 208 and 210 such that a residual image of the upper sideband channel 204 will substantially not interfere with the lower channels 208 and 210 . The wavelength λ of each channel is expressed in terms of difference between the wavelength of the channel and the wavelength of the carrier. So if a channel is denoted λ 1 , that means that the channel has a wavelength of λ c +λ 1 . Thus, in the signal of FIG. 3 a, an upper sideband channel has a wavelength λ 1 and neither lower sideband channel 208 , 210 has a wavelength equal to the wavelength of the carrier 200 minus λ 1 . FIG. 3 b shows one band B′ of a double optical single sideband signal in which each upper sideband channel 204 ′, 206 ′ has a corresponding lower sideband channel 208 ′, 210 ′. The signal 212 has a carrier 200 ′.
[0027] [0027]FIG. 4 shows a plurality of channels λ 1 . . . λ 10 contained in two bands B 1 , B 2 or ITU-grid windows. The channels of each band B 1 , B 2 include four data channels on respective sub-carriers 220 and one continuous wave carrier 222 which is umnodulated. The signal 224 shown in FIG. 4, may represent, for example, a ultra-dense wavelength division multiplexed on-off key modulated signal (U-DWDM OOK). Though four channels are shown in each of FIGS. 3 a, 3 b and 4 , different numbers of channels may be used, depending on the channel spacing and window size.
[0028] In operation, referring to FIGS. 1 - 4 , add/drop node 100 an input optical signal from the transmitter 106 is received by the input 102 . The input optical signal may be, for example, similar to one of those signals shown in FIGS. 3 a, 3 b and 4 . The input signal has a plurality of components, each component having a different wavelength from the other components. The input signal is amplified by the optical amplifier 108 and continues to the optical pre-filter 110 . As noted above, the optical pre-filter 110 preferably has a band pass bandwidth approximately the same as the width of a band B n of the input optical signal, e.g. about 40-80 GHz, so that only one band of the input optical signal is processed by the add/drop node 100 .
[0029] The input optical signal enters the circulator 112 and passes into the upper arm of the add/drop circuit. The optical filter 114 is a band pass filter which separates one component, the unmodulated carrier 200 , 200 ′, 222 , from the signal. The signal proceeds through the optical isolator 116 and the polarization controller 118 before entering the modulator 120 . The modulator 120 receives an information signal and modulates the carrier 200 , 200 ′, 222 with the information signal. Preferably, the information signal is modulated onto the carrier in a channel corresponding to the channel to be dropped; it may be placed in any empty channel, or even out of band, if there is not to be interference from an adjacent band.
[0030] When the optical filter 114 passes the carrier into the upper arm, it also reflects a portion of the input optical signal, i.e. all but the optical carrier, back through the circulator 112 and into the lower arm. The notch filter 130 removes the carrier and the signal proceeds to the second circulator 132 . Even in the case where the filter 114 has removed most of the carrier, there may be residual components of the carrier which should be removed by the notch filter 130 . The two optical filters 134 , 136 along with the optical isolator 138 act as a strong, narrow bandpass filter to extract a second component, the channel to be dropped, from the signal. The use of the two filters 134 , 136 and the isolator 138 allows the dropped channel to be more completely removed from the signal, reducing residual components which might interfere with adding a new channel. The filters 134 , 136 may be tunable so that any selected channel can be dropped.
[0031] In most circumstances, the dropped channel will be dropped so that it may be locally received. In those cases, a photodetector 140 is used to receive the dropped channel after it passes through the filters 134 , 136 . In the case that the dropped channel is being dropped simply to free bandwidth for a channel to be added and is not to be locally used, no photodetector 140 is required. A termination (not shown) should be used to ensure reflections are effectively eliminated, though this may not be necessary given the isolator 138 .
[0032] The first filter 134 reflects the remaining optical signal, without the dropped channel, onward towards the output optical path 122 . The signal passes through the combiner 126 where it is combined with the carrier which has been modulated with the information signal, forming an output optical signal. The output optical signal is optionally amplified by the optical amplifier 124 and is output from the add/drop node 100 for further transmission to a receiver (not shown).
[0033] Since the upper and lower arms of the circuit are recombined at the combiner 126 , it is desirable to match the optical path lengths so that the output optical signal components retain similar phase relationships to each other as they had prior to processing in the add/drop node 100 . This is of particular importance, for example, in a packet-switched network. In order to maintain phase relationships, delay loops, for example, can be added into whichever of the two arms has a shorter optical path.
[0034] [0034]FIG. 5 shows an extension of the add/drop 100 of FIG. 1, adapted to add and drop up to N channels. The components of add/drop 300 are similar to add/drop 100 . The input 302 may include an optical amplifier 308 prior to the optical pre-filter 310 . The circulator 312 is in communication with an upper arm of the circuit including an optical filter 314 for separating the carrier from the optical signal. The optical filter 314 is in communication with a polarization controller 318 and a modulator 320 . The modulator 320 is in communication with a separate input 321 for inputting information signals to be modulated onto the carrier as in the add/drop 100 of FIG. 1.
[0035] In the lower arm, a series of drop filters 334 and photodetectors 340 are used to drop each channel to be dropped. As can be seen, circulators 332 are used to direct the signal into each drop filter 334 seriatim. Though drop filters 334 are shown as a single component in FIG. 5, they may be understood to encompass an arrangement such as that shown in FIG. 1, each filter 334 including two bandpass filters in conjunction with an optical isolator. N sets 341 of filters 334 and photodetectors 340 are provided to drop N channels.
[0036] At the junction of the two arms, a combiner 326 is provided to combine the two signals for output.
[0037] The operation of the add/drop 300 may be understood from the operation of the add/drop 100 described above without further explanation. There is some upper limit on the number of channels N which can be added at each add/drop 300 . Though, in theory, the number of drops could be extended without a practical limit, the adding modulator generally has a maximum bandwidth. The maximum number of added channels may be derived from the maximum bandwidth, the channel width and the channel spacing and will depend on the application, as well as changes in standards and technologies.
[0038] Embodiments of the present invention find uses, for example, in all-optical, packet-switched networks having fast optical switches and routers in the core or circuit-switched networks with relatively slow optical cross-connects for providing traffic re-routing or protection functions. Such networks may be used as telecommunications networks carrying voice and/or data, CATV networks or other such applications.
[0039] While the invention has been described in connection with particular embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but on the contrary it is intended to cover various modifications and equivalent arrangement included within the spirit and scope of the claims which follow. | A method and device for optical add/drop is disclosed. The add/drop splits an input signal into two portions. The first portion is optically filtered to remove the channels, leaving an unmodulated carrier which is modulated with the newly added information. The second portion is split again into the through channels and a channel to be dropped. The dropped channel is detected or terminated and the through channels are recombined with the newly added channel to form an output optical signal. If desired, multiple channels may be dropped at the add/drop node. A dense wavelength division multiplexed (DWDM) optical communication system incorporating the add/drop node is also disclosed. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of co-pending U.S. provisional patent application Ser. No. 60/943,173, filed Jun. 11, 2007, which application is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] This invention relates to the extraction and upgrading of fossil fuels and in particular, the upgrading of bitumen using supercritical fluids.
BACKGROUND OF THE INVENTION
The Substrate
[0003] The Athabasca tar sands in Alberta are estimated to contain at least 1.7 trillion barrels of oil, and as such may represent around one-third of the world's total petroleum resources. Over 85% of known bitumen reserves lie in this deposit, and their high concentration makes them economically recoverable. Other significant deposits of tar sands exist in Venezuela and the USA, and similar deposits of oil shale are found in various locations around the world. These deposits consist of a mixture of clay or shale, sand, water and bitumen. Bitumen is a viscous, tar-like material composed primarily of polycyclic aromatic hydrocarbons (PAHs). Extraction of the useful bitumen in tar sands is a non-trivial operation, and many processes have been developed or proposed. Lower viscosity deposits can be pumped out of the sand, but more viscous material is generally extracted with superheated steam, using processes known as cyclic steam stimulation (CSS) or steam assisted gravity drainage (SAGD). More recently, this latter technology has been adapted to use hydrocarbon solvents instead of steam, in a vapor extraction (VAPEX) process. Supercritical fluids (SCFs) have been considered a potentially attractive extractant for bituminous deposits since the 1970s. Their low densities and low viscosities make them particularly effective at permeating tar sands and oil shales and extracting organic deposits, and the energy costs associated with the moderate temperatures and pressures required to produce them compare very favourably with those processes that use superheated steam. For example, bitumen has been successfully recovered from Stuart oil shale in Queensland using supercritical carbon dioxide (scCO 2 ), and from Utah oil sands using supercritical propane (sc propane). Very recently, Raytheon announced the use of scCO 2 in combination with RF heating to extract oil shale deposits beneath Federal land in Colorado, Utah and Wyoming.
[0004] Bitumen typically contains around 83% carbon, 10% hydrogen and 5% sulfur by weight, along with significant ppm amounts of transition metals like vanadium and nickel associated with porphyrin residues. This low-grade material commonly needs to be converted into synthetic crude oil or refined directly into petroleum products before it can be used for most applications. Typically, this is carried out by catalytic cracking, which redistributes the hydrogen in the material. Catalytic cracking produces a range of ‘upgraded’ organic products with relatively high hydrogen content, but leaves behind a substance known as asphaltene, which is even more intractable than bitumen and contains very little hydrogen. Unless this asphaltene is upgraded by reaction with hydrogen, it is effectively a waste product.
SUMMARY OF THE INVENTION
[0005] In one aspect, the invention relates to a process for extracting and upgrading a hydrocarbon. The process comprises the steps of providing a substrate containing a hydrocarbon comprising at least one of oil, tar and bituminous material to be extracted and upgraded; providing a reaction medium comprising hydrogen gas, a catalyst, and a supercritical or near-critical solvent that serves to extract the at least one of oil, tar and bituminous material from the substrate, and that serves to dissolve the hydrogen gas; mixing the substrate, supercritical or near-critical solvent, hydrogen gas, and the catalyst; and maintaining the mixture at temperature sufficient to cause reaction for a length of time calculated to allow said reaction to proceed to a desired extent. By this process, oil, tar or bituminous material is extracted and upgraded in a unitary operation.
[0006] In one embodiment, the process further comprises the step of providing a modifier. In one embodiment, the modifier is toluene or methanol. In one embodiment, the process further comprises the step of sonication. In one embodiment, the process further comprises the step of photochemical activation. In one embodiment, the hydrocarbon comprises at least one of bitumen and a polycyclic aromatic hydrocarbon (PAH). In one embodiment, the substrate comprises at least one of oil sand, oil shale deposits, and tar sand. In one embodiment, the PAH comprises at least one of naphthalene, anthracene, phenanthrene, pyrene, perylene, benzothiophene and indole. In one embodiment, the PAH contains nitrogen, sulfur, or a transition metal. In one embodiment, the supercritical or near-critical solvent is carbon dioxide.
[0007] In one embodiment, the catalyst comprises at least one of Mn 2 (CO) 8 (PBu 3 ) 2 , RuH 2 (H 2 )(PCy 3 ) 2 , Pd, Pt, Ru, Ni Rh, Nb, and Ta. In one embodiment, the process further comprises the step of providing a co-solvent. In one embodiment, the co-solvent is a selected one of n-butane and methanol. In one embodiment, the supercritical or near-critical solvent is a selected one of hexane and water. In one embodiment, the catalyst comprises at least one of α-Al 2 O 3 , HfO 2 , ZrO 2 , NiMo, Fe, Ni, Ru, Ru, Pd, Pt, and Ir.
[0008] In some embodiments, the step of maintaining the mixture at temperature sufficient to cause reaction comprises maintaining the mixture at a temperature in the range of 50° C. to 400° C. In some embodiments, the step of maintaining the mixture at temperature sufficient to cause reaction comprises maintaining the mixture at a temperature in the range of 50° C. to 150° C. In some embodiments, the step of maintaining the mixture at temperature sufficient to cause reaction comprises maintaining the mixture at a temperature in the range of 250° C. to 350° C.
[0009] In some embodiments, the step of providing a reaction medium comprising hydrogen gas, a catalyst, and a supercritical or near-critical solvent comprises providing said supercritical or near-critical solvent at a pressure in the range of 50 bar to 1000 bar. In some embodiments, the step of providing a reaction medium comprising hydrogen gas, a catalyst, and a supercritical or near-critical solvent comprises providing said supercritical or near-critical solvent at a pressure in the range of 100 bar to 500 bar. In some embodiments, the step of providing a reaction medium comprising hydrogen gas, a catalyst, and a supercritical or near-critical solvent comprises providing said supercritical or near-critical solvent at a pressure in the range of 150 bar to 400 bar.
[0010] Combining the operations of extraction, distillation, coking and upgrading will allow for major cost savings in energy, capital equipment and plant and process management systems. It will also have the added advantage of permitting significant reductions in CO 2 emissions through increased efficiency.
[0011] The foregoing and other objects, aspects, features, and advantages of the invention will become more apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The objects and features of the invention can be better understood with reference to the drawings described below, and the claims. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views.
[0013] FIG. 1 is a schematic diagram of an oil sands petrochemicals process with integrated distillation, coking and upgrading.
[0014] FIG. 2 is a graph showing hydrogenation of naphthalene as a function of initial concentration of naphthalene according to one embodiment of the invention.
[0015] FIG. 3 is a graph showing the hydrogenation of naphthalene as a function of time according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] This invention teaches a combined SCF process for extracting and upgrading bitumen, thereby enabling a more efficient and integrated procedure for use in the processing of low-grade petroleum deposits in tar sands and/or oil shales. While supercritical fluids have been used to extract oil and bituminous materials from sand and shale deposits, and have been used as reaction media for a range of homogeneous and heterogeneous chemical processes, they have never been used in the combined extraction/chemical reaction process of this invention. In this invention, mining or in situ extraction produces bitumen that feeds into a combined distillation, coking and upgrading process.
Solubility and Extraction of Bitumen in SCFs
[0017] Bitumen is a semi-solid material consisting of a mixture of hydrocarbons with increasing molecular weight and heteroatom functionalities. If bitumen is dissolved in hydrocarbons such as n-heptane, a precipitate known as asphaltene forms. This is the most complex component of crude oil, consisting of large PAHs. It has been shown that asphaltenes are soluble in toluene but insoluble in n-heptane at reasonable temperatures, which indicates that it is possible to form bituminous solutions. Solubilities of tar sand bitumen in scCO 2 have been reported at temperatures between 84° C. and 120° C. These studies reveal that its solubility is temperature- and pressure-dependent, with low temperatures and higher pressures giving optimum solubilities.
Supercritical Fluid Reaction Media
[0018] In addition to their excellent extraction properties, supercritical fluids have developed recently into unique and valuable reaction media, and now occupy an important role in synthetic chemistry and industry. They combine the most desirable properties of a liquid with those of a gas. These include the ability to dissolve solids and total miscibility with permanent gases. This is particularly valuable in the case of hydrogen, whose low solubility in conventional solvents is a major obstacle to synthetic chemists. For example, scCO 2 with 50 bar of added H 2 at 50° C. is 3 M in H 2 , a concentration that cannot be reached in liquid benzene except at an H 2 pressure of 1000 bar.
[0019] Two US patents describe the application of SCFs to the upgrading and cracking of heavy hydrocarbons. U.S. Pat. No. 4,483,761 describes the addition of light olefins to an SCF solution, and U.S. Pat. No. 5,496,464 describes the hydrotreating of such a solution.
Carbon Dioxide, CO 2
[0020] With its low T c , P c , and cost, CO 2 has found many applications as a SCF medium for a range of processes. It is already established as an excellent extraction medium, and has demonstrated utility in the extraction of bituminous materials from tar sands and oil shale, as described above. The low T c for CO 2 means that an effective operating range for this medium will be 50-150° C. This is significantly lower than the temperatures required for thermal cracking of PAHs and asphaltenes into smaller volatile fractions, but significant advantage may be gained by a pre-hydrogenation step, as this will furnish a hydrogen-enriched substrate that will provide increased yields of upgraded materials in any subsequent cracking stage. PAHs like anthracene, phenanthrene, pyrene and perylene have been shown to be surprisingly soluble in scCO 2 , and the fluid is an excellent hydrogenation medium. There is extensive literature on catalyzed organic hydrogenation reactions in scCO 2 . Of specific interest is research carried out on highly unsaturated and aromatic substrates such as naphthalene and anthracene. Simple PAHs such as naphthalene, anthracene, pyrene and phenanthrene have been successfully hydrogenated to the corresponding hydrocarbon in conventional solvents using homogeneous metal carbonyl catalysts like Mn 2 (CO) 8 (PBu 3 ) 2 , and RuH 2 (H 2 )(PCy 3 ) 2 , although homogeneous hydrogenations usually require severe reaction conditions and are not widely reported. Heterogeneous conditions using a range of transition metal systems, including alumina-supported Pd and Pt, and a reduced Fe 2 O 3 system are effective hydrogenation catalysts at reasonably low temperatures (<100° C.). Both naphthalene and anthracene have been hydrogenated with a supported Ru catalyst, and anthracene has been upgraded in this way using an active carbon-supported Ni catalyst. Of particular interest in this regard is a recent report describing the facile hydrogenation of naphthalene in scCO 2 in the presence of a supported Rh catalyst in 100% yield at the low temperature of 60° C. Homogeneous hydrogenation of heteroaromatic molecules such as benzothiophene (S containing) and indole (N containing) has been successfully demonstrated with a variety of simple catalysts at reasonable temperatures (<100° C.), with no poisoning of the catalysts by the heteroatom components. Photolysis of benzo[α]pyrene, chrysene and fluorene has been carried out in a water/ethanol mixture in the presence of oxygen to form a variety of ring opening products. There are few reports of photochemical transformations carried out in SCFs; however the transparency of CO 2 across much of the UV region of the spectrum allows substitution of ethanol with scCO 2 while still achieving similar photolysis results with PAHs in this medium.
Hexane, C 6 H 14
[0021] Hexane offers an intermediate operating range (ca. 250-350° C.). Supercritical propane has been demonstrated as a direct extraction technology, and the recovery of bitumen from mined tar sands using a light hydrocarbon liquid is a patented technology. In the temperature regime of scC 6 H 14 , thermal rearrangement of the carbon skeleton becomes accessible. For example, alumina-supported noble metal catalysts have been used in the ring-opening of naphthalene and methylcyclohexane at 350° C., and substantial isomerization of the ring-opened products was observed. Homogeneous rhodium-catalyzed ring opening and hydrodesulfurization of benzothiophene has been shown to be successful at 160° C. with relatively low pressures of hydrogen (30 bar) in acetone and THF. The high concentrations of H 2 that can be supported in the SCF medium, in tandem with a heterogeneous hydrogenation co-catalyst (q.v.), is likely to result in simultaneous hydrogenation of ring-opened intermediates and their isomers, breaking up the high molecular weight unsaturated aromatic molecules and turning them into volatile aliphatic materials.
Water, H 2 O
[0022] Supercritical H 2 O (scH 2 O) has found utility in promoting a wide range of organic reactions, including hydrogenation and dehydrogenation; C—C bond formation and breaking; hydrolysis; and oxidation. Hydrogenation of simple PAHs and heteroaromatic hydrocarbons in the presence of sulfur-pretreated NiMo/Al 2 O 3 catalysts has been demonstrated in scH 2 O at 400° C. This medium possesses properties very different from those of ambient-temperature water, including a decreased dielectric constant, a diminished degree of hydrogen bonding and an enhanced (by three orders of magnitude) dissociation constant. Accordingly, many organic compounds are highly soluble in scH 2 O, and the pure fluid is an excellent environment for acid- and base-catalyzed reactions. SCH 2 O has recently been shown to act as an effective medium for the gasification of biomass derived from lignin, glucose and cellulose, because at temperatures around 400° C. major degradation and reorganization of the carbon skeleton occurs. Thus, pyrolysis in the presence of high amounts of dissolved H 2 and a Ni or Ru catalyst leads to a range of volatile products such as CO, CO 2 and CH 4 . This represents a significant improvement over conventional gasification procedures, which operate at 700-1000° C. Hydrogenations of simple PAHs and heteroaromatic hydrocarbons in the presence of sulfur pretreated NiMo/Al 2 O 3 catalysts have also been shown to be successful in scH 2 O at 400° C.
[0023] In principle, carbon dioxide, hexane and water as supercritical fluid reaction media are capable of integration with an extraction technology: scCO 2 has been demonstrated as an effective medium for the extraction of bitumen from tar sand and oil shale deposits; sc propane has been used to extract bitumen from oil sands, and the outflow from current CSS, SAGD or VAPEX extraction technologies may be easily converted into a supercritical bitumen-water mixture. Use of scH 2 O appears to be unexplored in tar sands technologies.
Catalysts
[0024] The enhanced miscibility of H 2 with scCO 2 has found a wide range of applications in homogeneous catalysis, including enantioselective preparation of fine chemicals like the herbicide (S)-metolaclor by Novartis. Facile hydroformylation of propene using a CO 2 (CO) 8 catalyst has also been demonstrated, and an enhanced selectivity for the linear product n-butyraldehyde was observed compared with a conventional liquid solvent. Olefin metathesis, involving the breaking and rearrangement of C═C bonds, has been demonstrated in SCF media under mild conditions. A range of heterogeneous hydrogenation reactions has also been carried out successfully in scCO 2 , including Fischer-Tropsch synthesis using a Ru/Al 2 O 3 or a Co/La/SiO 2 catalyst system. Heterogeneous Group 8 metal catalysts are also very effective in the synthesis of N,N-dimethylformamide from CO 2 , H 2 and Me 2 NH under supercritical conditions, and the hydrogenation of unsaturated ketones using a supported Pd catalyst has been carried out under mild conditions in scCO 2 .
[0025] Oil, tar or bituminous material from oil sand or oil shale deposits can be extracted using a supercritical or near-critical solvent. The solubility of bitumen in supercritical CO 2 and supercritical hexane can be increased, and subsequently its extraction from tar sands can be enhanced by adding modifiers such as toluene or methanol and by using sonication to encourage dissolution. Sonication has recently been claimed to accelerate chemical reactions in a supercritical fluid medium.
[0026] In one embodiment of the invention, carbon dioxide is used as a supercritical medium for the combined extraction and upgrading process. Carbon dioxide has the most accessible critical temperature and is cheap, but lacks polarity and will be limited to a low temperature upgrading process. Modifiers such as toluene or methanol can be added to help dissolve bituminous material.
[0027] In another embodiment of this invention, hexane is used as a supercritical medium for the combined extraction and upgrading process. It offers a medium temperature possibility, but also suffers from the lack of a dipole moment and is the most costly of the three medium.
[0028] In another embodiment of this invention, water is used as a supercritical medium for the combined extraction and upgrading process. Water has the highest critical temperature. The polar nature and negligible cost of water are attractive characteristics.
[0029] An appropriate amount of hydrogen gas is introduced into this supercritical or near-critical mixture. The appropriate amount of hydrogen gas will vary according to the amount of unsaturation present in the hydrocarbon to be upgraded, and in relation to the proportion of hydrogen that is desired to be maintained in the reaction medium.
[0030] Hydrogenation and ring-opening reactions of simple PAHs like naphthalene and anthracene, and of more complex PAHs, including mixtures of PAHs containing heteroatoms like N and S, and transition metals, are conducted in these SCF media using a wide range of catalysts. Such mixtures are representative of the chemical constitution of bitumen and shale oil.
[0031] A number homogeneous and heterogeneous catalysts may be used with PAH substrates for a combination of hydrogenation and ring opening reactions in scC 6 H 14 , and cleavage, hydrogenation and gasification in scH 2 O. These homogeneous catalysts include Nb and Ta, which have been shown to be effective for the hydrogenation of a variety of arene substrates. Heterogeneous supported systems are likely to prove more robust and long-lived than homogeneous catalysts. For scCO 2 , there is a wide range of commercially available hydrogenation catalysts including heterogeneous Ni and Ru systems supported on alumina or carbon, and metals like Rh and Pt that can be costly.
[0032] Small amounts of co-solvents like n-butane and methanol can also be added to the scCO 2 medium to enhance the solubility of PAHs in scCO 2 .
[0033] The reaction mixture can be activated by photochemical irradiation using light in the ultraviolet and/or visible region of the electromagnetic spectrum. This activation can be used to accelerate the ring-opening, fragmentation and hydrogenation reactions involved in the upgrading process.
[0034] Only the most robust catalysts will be compatible with the reactive and/or high temperature environment in scC 6 H 14 and scH 2 O. However, α-Al 2 O 3 , HfO 2 and ZrO 2 are all physically and chemically stable under these conditions, and can be used to support finely divided metal catalysts. Late transition metals like Fe, Ni, Ru, Rh, Pd and Pt are effective hydrogen transfer catalysts to unsaturated organic moieties including the aromatic rings of PAHs, whereas Ru and Ir are known to be good catalysts for ring-opening and olefin metathesis.
[0035] Development of an optimal heterogeneous supported catalyst that combines these two processes under supercritical conditions is an iterative process necessitating a combinatorial approach at the outset. However, the simple expedient of e.g. impregnating Al 2 O 3 with stock solutions of metal salts, followed by drying and reduction with H 2 gas is remarkably effective in producing high activity catalysts for these types of processes.
[0036] The reaction mixture is maintained at an appropriate temperature for an appropriate length of time to effect the desired hydrogenation, rearrangement, or degradation of the bituminous material in the mixture. The required temperature and length of time will vary depending on the concentration of reagents in the system and the quantity of material that one wishes to upgrade.
[0037] The following examples are intended to be illustrative of embodiments of the present invention. Those of skill in the art may effect alterations, modifications and variations to the particular embodiments without departing from the scope of the invention, which is set forth in the claims.
Example #1
[0038] Hydrogenation of naphthalene, a PAH, was carried out in the presence of Rh/C with H 2 (60 bar, 870 psi) and scCO 2 (100 bar, 1450 psi). Reactions were carried out for 16 hours according to the reaction conditions shown in Scheme 1.
[0000]
[0039] FIG. 2 is a graph showing hydrogenation of naphthalene as a function of initial concentration of naphthalene, in which the amount of naphthalene is indicated by diamonds, the amount of tetralin is indicated by squares, and the amount of decalin is indicated by triangles. The vertical axis represents relative concentration of hydrocarbon in percent total hydrocarbon, and the horizontal axis represents initial concentration of naphthalene in moles.
[0040] The reaction was repeated using naphthalene concentrations of 0.1 M, 0.2 M, 0.3 M, 0.4 M, and 0.5 M. Under these reaction conditions, total hydrogenation of naphthalene was achieved at concentrations greater than 0.1 M. The result at 0.4 M is possibly due to errors associated with new equipment.
Example #2
[0041] Hydrogenation of naphthalene, a PAH, was carried out by mixing 0.1 M naphthalene in the presence of Rh/C with H 2 (60 bar, 870 psi) and scCO 2 (100 bar, 1450 psi) at 60° C. The percentage of tetralin and decalin formed was analyzed at 30 minutes, 1 hour, 2 hours, 3 hours and 4 hours. FIG. 3 is a graph showing the hydrogenation of naphthalene as a function of time, in which the amount of naphthalene is indicated by diamonds, the amount of tetralin is indicated by squares, and the amount of decalin is indicated by triangles. The vertical axis represents relative concentration of hydrocarbon in percent total hydrocarbon, and the horizontal axis represents duration of the reaction process in units of hours.
[0042] As indicated in FIG. 3 , 80% of naphthalene was converted to tetralin (50%) and decalin (30%) within 30 minutes. As the reaction time increased, naphthalene decreased further and formations of products increased. After 4 hours 90% of naphthalene had been converted to fully saturated decalin. Therefore, it is believed that only about 4 hours is required for complete hydrogenation, rather than 16 hours.
[0043] While the present invention has been particularly shown and described with reference to the structure and methods disclosed herein and as illustrated in the drawings, it is not confined to the details set forth and this invention is intended to cover any modifications and changes as may come within the scope and spirit of the following claims. | The invention provides systems and methods for extracting and upgrading heavy hydrocarbons from substrates such as oil sands, oil shales, and tar sands in a unitary operation. The substrate bearing the hydrocarbon is brought into contact with a supercritical or near-supercritical fluid, a source of hydrogen such as hydrogen gas, and a catalyst. The materials are mixed and heated under elevated pressure. As a consequence of the elevated temperature and pressure, upgraded hydrocarbon-containing material is provided in a single or unitary operation. In some embodiments, sonication can be used to improve the upgrading process. Fluids suitable for use in the process include carbon dioxide, hexane, and water. It has been observed that upgrading can occur within periods of time of a few hours. | 2 |
BACKGROUND
1. Field of the Invention
This invention relates generally to methods for restoring data from damaged or corrupted computer files, specifically to a method for uniquely encoding database files, and using the encoding method to accomplish reliable error detection and restoration of the database files after they are corrupted.
2. Introduction
One of the primary uses for computers, whether for personal desktop computers or mainframe computers, concerns the processing of database information. A database is a collection of information arranged in an organized, easier-to-find manner. A typical database might include financial and accounting information, demographics and market survey data, bibliographic or archival data, personnel and organizational information, public governmental records, private business or customer data such as addresses and phone numbers, etc.
Database information is usually contained in computer files arranged in a pre-selected database format, and the data contents within them are maintained for convenient access on magnetic media, both for storage and for updating the file contents as needed.
A conventional computer database, of the dBase type, comprises a data record file having a plurality of fixed byte-length records; and an optional file, for storing larger variable byte-length data, commonly known as the memo file. Both types of files typically include a file header with file structure information, and a data region that contains the useful data. The record file header may contain file structural information such as byte-length of a record, position of the first record in a file, and number of records in a file. The memo file header typically contains the location of the next available memo position. Variation might exist, to include for example information within the header indicating other formatting details or other characteristics of the file contents. Corruption of header errors is not difficult to detect or repair. A more difficult task involves detecting errors and restoring the contents of data regions in either record or memo files, when such files become corrupted or damaged.
In a record file, the data region consists structurally of one or more equal length records positioned sequentially one after the other at fixed interval positions in the file structure. Each record is subdivided into one or more fields, with each field containing a single type of data such as binary, alphanumeric or other type of data. Each record has the same number of fields and same field types. One or more of the fields may also be memo fields storing memo pointers. Memo pointers are numerical values which indicate the positions of "memos", the variable byte-size data units in the memo file. Instead of individual byte-count memo size variations, sometimes memos are made up of larger sized entities called "memo blocks", each block of memo data having a suitably convenient predetermined byte size, e.g. 512 bytes. In older database memo files, such as Borland dBaseIII, memos were only constructed to store text information. However, newer memo files, such as Microsoft FoxPro memo files, can also store graphics, multimedia, or any other digital or binary-coded information. For purposes of this invention, no distinction is made between these different memo file data unit types, and they are simply referred to as memos.
A database file may be corrupted (damaged) for a number of reasons, including application program bugs, the crashing of the database application program, the crashing of the operating system, and the rebooting of the computer when the program is running, among other reasons. Corruption may occur in the header and/or the data region. Corruption in the data region may include offsets that separate adjacent valid records or memos by extraneous bytes; incorrect memo pointers that reference wrong memos; illegal memo pointers that reference non-existent memos; and cross-linked memo pointers that reference the same memo. Offsets disrupt the structural positions of records or memos, i.e., they cause the records or memos to be arranged at incorrect byte-count positions within their respective files.
The description of prior art and preferred embodiment focuses on dBase type databases having separate record and memo files. However, concepts discussed can be applied to database files having records, memos and other information combined in a single file, such as Microsoft Access and similar database files.
3. Description of Prior Art:
A variety of approaches have been suggested for users of computer database programs, as suitable means for ensuring data integrity and restoring corrupted database files. Such error detection and restoration methods found in the prior art can be classified into three categories.
The first category is a simple periodic backup, in which duplicates of the files are made on either the same storage device, such as a hard disk, or a separate storage device, such as a backup diskette, tape cassette or other removable media. Errors are detected in such a system only when the system fails or the errors are grossly apparent, while small cumulative errors in data may go undetected for extended periods of time. Furthermore, data entered or generated since the last backup cannot be recovered after database becomes corrupted. Also, many users fail to make periodic backups.
The second category provides automatic duplication of data or transaction loging on the same or another storage device. Examples of such and similar systems are disclosed in U.S. Pat. Nos. 5,280,611; 5,404,502; and 5,404,508. When data becomes corrupted the same or secondary device still has the uncorrupted data available. However, such real-time recovery systems are only adaptable to large system installations, requiring expensive hardware and software support often beyond the budget of individuals and small businesses.
The third category includes file repair utilities (FRU's) known to the prior art which can provide some amount of protection from file damage and corruption, but are nonetheless limited in many respects. A first type of FRU, such as "Norton Utilities FileFix" published by Symantec, has limited capability since it repairs only header damage. It cannot detect errors in the data region, and cannot effect necessary repairs to prevent file damage in the data region. Furthermore, it must be activated by a user, and requires the user to stop using the application program while the FRU is in operation. A second type of FRU, such as "dSalvage", distributed by Hallogram Publishing, can be used to repair both header and data region damage, but requires manual user intervention and considerable user skills in its operation and furthermore has limited error detection capability. A third type of FRU, such as "FoxFix", developed by XiTechnics Corporation, is substantially automatic, and requires no user interaction. It is fast and efficient, but it can detect and repair only very limited data region corruption problems. For example, it cannot reliably detect or repair offset record damage, nor resolve incorrect, illegal or cross-linked memo pointers.
Error detection methods incorporated in prior art FRU's have attempted to ensure file integrity of database files by one of three types of approaches, each of them having serious limitations: The first type of approach involves detection of record offset errors in the record file. There is no reliable way to scan through the record file and determine that each record is where it is supposed to be. An example method attempts to scan the first byte of each proper record position for the traditional delete flag which can contain either a space, `` character, or a `*` deleted flag character. Anything else indicates a record error. However, normal data in the rest of the record may contain `*` characters and spaces are frequent. Hence detecting those two characters in first byte is not an indication of correct record positions.
The second type of approach detects offset errors in the memo file. Both traditional dBase files and newer file variations lack unique characters to indicate the starting position of a memo in a memo file. One exception is FoxPro file memos, which use a 0001 (hex) and 0002 (hex) byte value sequence at the start of memos to distinguish text memos from graphical memo types. However, this is not a reliable means for locating memos, since 0 byte values are very common in memo files and can be followed by a random 1 or 2 byte value.
A third type is detection of memo pointer errors. The only two such errors that can be detected by prior art FRU's are illegal pointers, those which point beyond the end of the file, and, in some cases, invalid pointers, those which do not point to a memo start position or where plurality of pointers point to the same memo. The plurality of memo pointers pointing to same memo are sometimes referred to as cross-linked pointers. There is no prior art found in any FRU software providing a method to determine which of the cross-linked memo pointers is correct, nor a method how to correct the other memos. Furthermore, the available prior art cannot in fact determine that a pointer is correct. A pointer can be the only pointer to reference a valid memo position, yet it may reference an incorrect memo.
Reliable error detection is important not only in cases when data corruption become obvious to the program user, but also in cases when no errors are apparent. Business and government operations with accumulating undetected errors can have serious consequences.
OBJECTS OF THE INVENTION
Accordingly an object of the present invention is to provide an economical but significantly improved capability for consistent and reliable error detection and for similarly reliable data recovery including the detection and repair of: record file data region corruption such as record dislocations; illegal, incorrect and cross-linked memo pointers; and memo file data region corruption, such as memo dislocations.
Yet another object of the present invention is to provide a method for error detection and restoration of database files that is substantially automatic in its operation, so that virtually no end user interaction is required. Further objects of the present invention will become apparent from a consideration of the drawings and ensuing description.
SUMMARY OF THE INVENTION
A method of error detection and restoration of database files comprises generating a unique record code in each record of the record file, and when a memo file is present, generating a unique memo code in each memo of the memo file for identifying the correlation of the memo to one particular record field and one uniquely identified record. This correlation, along with the requirement that record codes and memo codes have specific locations, provides a basis for a computer programmed algorithm that can be used to accurately detect both record file and memo file structural corruption, locate and associate memos in the memo file to records in the record file and subsequently repair database files.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows database files embedded with record and memo codes in accordance with a preferred embodiment of the invention.
FIG. 2 shows the database files after it is corrupted.
FIG. 3 shows the restored database files.
DRAWING REFERENCE NUMERALS
______________________________________10. Record File 11. Memo File12. Record File Header 13. Record File Data14-19. Fields Region21. Memo File Data 20. Memo File Header Region 22. Record Code Indicator23. Record Code Identifier 24. Memo Code Indicator26-29. Offsets R1-R4. RecordsRC1-RC4. Record Codes M1-M4. MemosMC1-MC4. Memo Codes P1-P4. Memo Pointers______________________________________
DESCRIPTION OF THE PREFERRED EMBODIMENT
The description following illustrates the case when both record files and memo files are included in the database. The simpler case of a database containing record files only, should be apparent from this description.
An exemplar intact database is comprised of a record file 10 and a memo file 11, as shown in FIG.1. Record file 10 includes a conventional file header 12 with file structure information (not shown), and a data region 13 that includes records R1 to R4 where useful information is stored. The records are located at fixed byte intervals, and are arranged in consecutive serial order according to the record file structure. Each record includes multiple fields 14-19 for storing categorized information formatted into fixed-length fields. Although only four records with six fields each are shown in the described example, record file 10 may include any number of records and fields. Records R1-R4 include respective record codes RC1-RC4 which are generated when the records are created. The record codes preferably occupy the first field 14 of each record, but they may occupy any other field if desired, and do not even have to be a field, but merely a code as part of the record structure. Memo file 11 includes a file header 19 and a data region 20 that includes memos M1-M4 where useful information is stored. Memos M1-M4 include respective memo codes MC1-MC4 which are generated when the memos are created. The memo codes preferably occupy the beginning of the memos, but they may be positioned elsewhere if desired. As shown in the example described, memos may be of variable length.
Each record code is comprised of a common record code indicator 22 and a unique identifier 23. In this example, code indicator 22 is "RECOVER", and identifiers 23 are sequentially generated numbers "001" to "004." Code indicator 22 may be user definable or automatically selected, and may be any other word, characters, or numbers. Identifiers 23 may be random numbers or characters. Each memo code is comprised of a memo code indicator 24, and the same identifier 23 of a corresponding record code. In this example, memo codes MC1-MC4 share the identifiers 24 of respective record codes RC1-RC4.
Fields 17 of records R1-R4 are pointer fields that include respective conventional pointers P1-P4 that point to corresponding memos M1-M4. In this example, the pointers are numbered to correspond with the numbers of the memos for the sake of simplicity, but in an actual database, the pointers usually point to memos in a random order, so that the pointer for the first record may point to the third memo, the pointer for the second record may point to the first memo, etc. Pointer fields are conventionally named with user definable names. The pointer field name is used for code indicator 24, which in this example is "SALES". Record file 10 and memo file 11 are generated by conventional methods well known in the art. Tables 1 and 2 are respective pseudo code listings for generating the record and memo codes. The pseudo codes are reducible to source codes in any desired computer language with conventional techniques. Each algorithm step is uniquely numbered. Comment lines are preceded by `//`.
TABLE 1______________________________________ Description caption for Table 1: Pseudo code listing forgenerating the record code indicator and record codeidentifier, when a new record is added to record file.!______________________________________101 Generate code indicator // Use same code indicator for all record codes, // e.g., "RECOVER"102 Generate record code identifier unique to each record // Identifiers may be random or sequential numbers, // characters, or a combination of both.103 Append identifier to code indicator104 Insert resulting record code in first field of new______________________________________ record
TABLE 2______________________________________ Description caption for Table 2: Pseudo code listing forgenerating the memo code indicator and memo code identifier,when a new memo is added to memo file.!______________________________________201 Get name of the pointer field in the current record and use it as the code indicator of the memo code // The code indicator for a memo code is the name of the // pointer field in a corresponding record, e.g. "SALES"202 Copy identifier from record code of the same record and append it to the code indicator of the memo code203 Insert resulting memo code at the beginning of the new memo______________________________________
Record file 10 and memo file 11 are shown corrupted in FIG. 2. In this example, the corruption of file integrity includes improper offsets 26-29, memos M1-M4 which are arranged out of sequence, cross-linked pointers P2 and P3 pointing to the same memo, and illegal pointer P4 which is pointing beyond the memo file. Table 3contains pseudo code listing of an algorithm for detection of errors within the record file, the memo file and the memo pointers. A pseudo code listing for the subsequent process needed to restore file integrity to the corrupted file, including both record files and memo files, is shown in Table 4. In both of these listings, the words `error` and `corruption` are used interchangeably, and indicate the same effect.
TABLE 3______________________________________ Description caption for Table 3: Pseudo code listing for errordetection.!______________________________________// record file error detection300 Check record file data region for corruption by verifying the location of record code indicators at all standard structural record positions.305 IF an error found, set record file error flag.// memo file error detection310 Check memo file data region for corruption by locating all memo code indicators and verifying that they are in correct structural positions.315 If error exists, set memo file error flag.// Memo pointers error detection320 DO for each non-zero memo pointer in record file321 Get memo code from memo field name and corresponding record code identifier.322 Check if the memo code can be found at correct structural position in memo file pointed to by the memo field pointer in the record.323 If any error, set memo pointer corruption flag. END DO______________________________________
TABLE 4______________________________________ Description caption for Table 4: Pseudo code listing for correctingerrors and restoring file integrity.!______________________________________// Repair record file data region if needed401 IF record file data region corrupt402 Search through record file for record code indicators.403 Rewrite file to eliminate offsets and place records in correct structural positions. END IF// Repair memo file data region if needed420 IF memo file data region corrupt421 Locate all memos in memo file by searching for memo code indicators and save locations of memos in temporary computer memory.422 Rewrite memo file to have located memos in correct structural positions423 Set memo pointer corruption flag END IF// Record file memo pointers repair430 IF memo pointers corrupt431 DO for each memo field pointer in record file432 Obtain memo code for correct memo from memo field name and record identifier code and check if the memo code is found at pointed to memo file position.433 IF memo field pointer indicates an incorrect memo // E.g., if memo code in step 432 not found at memo file // memo position pointed to.434 Search in memo file for memo having the memo code obtained in step 432440 IF correct memo found441 Change memo field pointer to indicate correct memo position ELSE // Point to no memo442 Set memo field pointer to 0 END IF END IF END DO END IF______________________________________
For both the record file 10 and the memo file 11, corruption or damage to file integrity is detected by verifying that record code indicators and memo code indicators are at structurally correct positions within their respective files; and by checking that memo pointers in records indicate positions of memos with correct memo code in the memo file.
When data integrity in the record file is damaged, the computer program of the present invention searches the entire damaged file for traces of the record code indicator, the first segment of the record code within every record which is a common inclusion for each record contained in the record file. The combination of the record code indicator in conjunction with the known record length then provides reliable information for recapturing the contents of the entire record. Similarly, when the contents of a memo file data region becomes corrupted, searching the entire file for memo code indicators, contained in the first segment of the memo code, provides locations of valid memo data in the memo file and provides means of restoring the memo file data region to structural integrity. When record file and memo file data regions are structurally restored, every memo pointer in the record file can be correctly re-associated with correct memo in the memo file by locating the corresponding memo code in the memo file.
The offsets of both files are thus eliminated, and their data regions are rewritten in their correct structural positions; the records are positioned at correct sequential record locations and the memos start properly at memo block intervals-for example, at conventional 512 byte intervals, if required. As shown in the drawings, the cross-linked pointer P3 and illegal pointer P4 are corrected, although after restoration, memos M1-M4 remain in the disrupted order caused by the corruption, i.e., arranged in the order: M3, M4, Ml, M2. As long as pointers P1-P4 are rewritten to point to the correct memo, the order of the memos is inconsequential.
The methods provided in Tables 1-4 are preferably incorporated in a database application program for automatically generating the record codes and memo codes when the database files are created, automatically checking for corruption, and automatically restoring the files, all without user intervention. Alternatively, corruption detection and restoration may be controlled by the program as independent processes, implemented as separate user selectable functions. The code generating and inserting functions may be incorporated into a compiler used for creating database application programs, so that application programmers are freed from having to create them. Any database application programs or any compiler that incorporates the devices and methods of the present invention may be preferably stored and distributed on a computer-readable storage medium, with the computer software program or compiler containing the necessary binary code required for specific system hardware and software not herein further defined or particularized with limitation. Accordingly, I have provided a method for encoding, corruption detection and restoration of database files. It detects, identifies and repairs record dislocations in the data region of record files. When memo files are present, the method detects memo dislocation errors and memo pointer corruption; repairs memo offsets; and identifies and resolves incorrect, illegal and cross-linked pointers. It is substantially automatic in its operation, so that no further user intervention or response is required.
The above descriptions are intended to be instances having illustrative value, and should not be considered as limitations on the scope of the invention. Many substitutes and variations are possible within the teachings of the invention. For example, the record and memo codes may contain binary or ASCII characters. Instead of the name of the pointer field, the code indicator of the memo codes may be the field number of the pointer field. The record code could include additional information about the original record sequence, or such information can be included in the code identifier. Furthermore, the methods for generating record and memo codes, error detection and checking and restoring the files may be varied. Conventional file header checking and restoring methods may be incorporated into the error detection and correction processes. Additional codes may be provided in a third file used by some database system for referencing the record and memo files. Some databases, like Microsoft Access with MDB file extensions, combine records, memos and other information in a single file. However, the records and memos are still inherently separate entities in the file so that record and memo encoding methods presented here could be used to identify and recover record and memo data reliably.
Therefore, the scope of the invention should be determined and limited only by the following appended claims and their legal equivalents. | An improved method for encoding, error detection and restoration of corrupted database files comprises generating a unique record code in each record of a record file, and when a memo file is present, generating a unique memo code in each memo of the memo file for identifying the correlation of the memo to one particular record field and one uniquely identified record. Error detection is achieved by verifying locations of record codes in record files; memo codes in memo files; and the correlation between memo codes in memo file and the record codes in record file. Integrity of record file is restored by searching for record codes and rewriting the located records in correct file structure positions. Memo file integrity is restored by searching for memo codes and rewriting memos in correct file structure positions, and memo pointers are corrected by using the method's correlation between record codes and memo codes to locate correct memos in the memo file. | 8 |
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application is a Continuation-in-Part of U.S. patent application Ser. No. 14/977,015 filed Dec. 21, 2015 entitled “Dispensing Brush” by Andre Sampaio, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to cleaning devices, and more specifically to a dispensing pad cleaner that delivers a cleaning solution from the device without the need for a separate cleaning solution dispenser.
[0004] 2. Description of Related Art
[0005] Scrubbers and other cleaning devices have been used throughout the years as tools to facilitate the cleaning of objects where undesirable material is stubbornly attached to the object, requiring mechanical abrasion of the undesirable material for proper cleaning. These devices often have an abrasive surface to provide cleaning action when the device is moved over the object to be cleaned, often times repeatedly. Devices to clean objects have taken on a variety of forms over the years, and have included many different abrasive surfaces and forms. A scrubber is a cleaning device that has some form of scrubbing surface or surfaces to abrade and remove undesirable material. A pad cleaner is a form of scrubber where the scrubbing surface of the cleaning device is formed as a pad. The scrubbing surface and material of the cleaning device may vary in composition, abrasiveness, form, thickness, or other factors to better suit the cleaning task at hand. For example, while a scrub brush may be suitable for cleaning grout lines in a shower, it would be cumbersome to use to clean a glass shower door. A scrubber with a suitably abrasive scrub pad would, however, make the cleaning of the glass shower door faster and more thorough.
[0006] While there are times when a cleaning device such as a scrubber or pad cleaner can be effectively used without a solvent or cleaning solution, often a cleaning solution, solvent or other such liquid will make the cleaning process easier and more effective. The cleaning solution is often applied to the object to be cleaned either before scrubbing with the cleaning device or during the scrubbing operation. The way in which the cleaning solution is applied in conjunction with the cleaning operation is often a matter of personal preference, and a variety of containers to retain the cleaning solution can be found in most stores. There are times when the container that retains the cleaning solution is not well suited for dispensing the proper amount of cleaning solution, and the resulting cleaning operation is either less than effective or the cleaning solution is wasted or over used. What is therefore needed is a pad cleaner with an integrated cleaning solution dispenser.
[0007] It is thus an object of the present invention to provide such a dispensing pad cleaner.
[0008] These and other objects of the present invention are not to be considered comprehensive or exhaustive, but rather, exemplary of objects that may be ascertained after reading this specification and claims with the accompanying drawings.
BRIEF SUMMARY OF THE INVENTION
[0009] In accordance with the present invention, there is provided a dispensing pad cleaner comprising a handle attached to a pad substrate; the pad substrate comprising a flexible material; a reservoir for liquid retention; a pump capable of receiving liquid from the reservoir; a dispensing nozzle to deliver liquid from the pump; a lever mechanically coupled to the pump such that movement of the lever causes actuation of the pump and subsequent dispensing of the liquid.
[0010] The foregoing paragraph has been provided by way of introduction, and is not intended to limit the scope of the invention as described in this specification, claims and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention will be described by reference to the following drawings, in which like numerals refer to like elements, and in which:
[0012] FIG. 1 is a perspective view of a dispensing pad cleaner of the present invention;
[0013] FIG. 2 is a rotated perspective view of the dispensing pad cleaner;
[0014] FIG. 3 is a rear plan view of the dispensing pad cleaner;
[0015] FIG. 4 is a front plan view of the dispensing pad cleaner;
[0016] FIG. 5 is a top plan view of the dispensing pad cleaner;
[0017] FIG. 6 is a bottom plan view of the dispensing pad cleaner;
[0018] FIG. 7 is a side plan view of the dispensing pad cleaner;
[0019] FIG. 8 is a perspective view of the dispensing pad cleaner showing the cleaning pad removed;
[0020] FIG. 9 is an exploded view of the dispensing pad cleaner;
[0021] FIG. 10 depicts a taper valve of the reservoir cap;
[0022] FIG. 11 depicts an engagement feature of the reservoir cap;
[0023] FIG. 12 depicts a pump actuator lever assembly of the dispensing pad cleaner;
[0024] FIG. 13 depicts a handle assembly of the dispensing pad cleaner;
[0025] FIG. 14 depicts a handle overlay of the dispensing pad cleaner;
[0026] FIG. 15 depicts a handle half of the dispensing pad cleaner;
[0027] FIG. 16 depicts a reservoir of the dispensing pad cleaner;
[0028] FIG. 17 is a side view of a pad substrate assembly of the dispensing pad cleaner;
[0029] FIG. 18 is a plan view of the pad substrate assembly of the dispensing pad cleaner;
[0030] FIG. 19 is a perspective view of the pad substrate assembly of the dispensing pad cleaner;
[0031] FIG. 20 is a perspective view of the pump of the dispensing pad cleaner; and
[0032] FIG. 21 is an exploded view of the pump of FIG. 20 .
[0033] The attached figures depict various views of the dispensing pad cleaner in sufficient detail to allow one skilled in the art to make and use the present invention. These figures are exemplary, and depict a preferred embodiment; however, it will be understood that there is no intent to limit the invention to the embodiment depicted herein. On the contrary, the intent is to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by this specification, claims and drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] A Dispensing pad cleaner is described and depicted by way of this specification and the attached drawings.
[0035] For a general understanding of the present invention, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements.
[0036] The Dispensing pad cleaner of the present invention, as described and depicted herein, provides, among other things, a novel liquid reservoir and dispensing mechanism that delivers a liquid such as a cleaning solution toward the working surface of the cleaning pad, thus improving the efficiency of the cleaning process and providing improved cleaning.
[0037] FIG. 1 is a perspective view of a dispensing pad cleaner of the present invention. The dispensing pad cleaner may be made from any suitable material, for example, a plastic. Examples of suitable plastics include acrylonitrile butadiene styrene (ABS), polyethylene, polypropylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, and the like. Bioplastics may also be used in some embodiments of the present invention. In addition, reinforced plastics, metals, wood, or other materials that may be suitably formed may also be used. The various components of the dispensing pad cleaner may be made by injection molding, blow molding, machining, extruding, forming, or the like. The various components are then assembled in accordance with the instructions and figures provided herein.
[0038] As can be seen in FIG. 1 , a dispensing pad cleaner 100 is shown comprising a handle and related handle assembly 105 attached to a pad substrate 113 . The pad substrate 113 may be flexible, and may be made from a material that has cushioning and flexibility, such as various polymers. An example of such a material is EVA (Ethylene-vinyl acetate). The pad substrate 113 may also be curved in some embodiments of the present invention. The pad substrate 113 retains a cleaning pad 115 . This pad 115 comprises an abrasive cleaning material such as a woven synthetic or plastic, for example, woven polyethylene, polypropylene, nylon, or the like. In some embodiments of the present invention, the pad 115 comprises a woven metal such as stainless steel, brass, or the like. The woven material, regardless of composition, may vary in abrasiveness and other properties depending on the cleaning application. The pad 115 may also be non-woven, and may comprise a cleaning fabric or other suitable cleaning material. In some embodiments of the present invention, the pad 115 may contain a cleaning material such as a detergent, bleach, cleaning particles, or the like. The pad 115 is formed such that it may be retained by the dispensing pad cleaner, specifically by fixtures designed to retain the pad 115 to the pad substrate 113 . As seen in FIG. 1 , an example of such retention means are provided. A first pad retention tab 117 can be seen as part of the pad 115 and a second pad retention tab 121 can be seen as well. In each retention tab a retention slot can also be seen. A first pad retention slot 119 can be seen transverse to the first pad retention tab 117 and a second pad retention slot 123 can be seen transverse to the second pad retention tab 121 . These slots each receive a pad hook, as further seen in FIG. 17 . The slots may be of various geometries, such as rectangular, circular, oval, or the like. A reservoir 107 for liquid retention can also be seen fixed below the handle and may, in some embodiments of the present invention, be shaped to conform to the underside of the handle. A pump (as shown in FIG. 9 as 903 ) is also part of the dispensing pad cleaner 100 and is capable of receiving liquid from the reservoir 107 when so filled. A dispensing nozzle 201 , as can be seen in FIG. 2 , is arranged to deliver liquid contained in the reservoir through the action of the pump 903 . A lever and related pump actuator lever assembly 111 is mechanically coupled to the pump 903 (as seen in FIG. 9 ) such that movement of the lever causes actuation of the pump and subsequent dispensing of the liquid contained in the reservoir 107 . The reservoir 107 can be seen clearly attached to the dispensing pad cleaner 100 such that it is integral with the dispensing pad cleaner 100 during a cleaning operation.
[0039] The handle assembly 105 comprises a front support beam 101 that is curved to conform to a user's hand and provides adequate width and structural integrity to support the reservoir 107 . In some embodiments of the present invention, the handle assembly 105 is made in two or more parts to accommodate placement of a pump and related structural elements within and attached thereto. Such structural details are shown by way of example, and not limitation, in FIG. 9 . The front support beam transitions into the main handle where a thumb rest 103 can be seen. The thumb rest may simply be a flattened area of the handle or may, in some embodiments of the present invention, be depressed or concave to more comfortably support the thumb or appendage of a user. As seen and taught by way of example in FIG. 1 , the reservoir 107 is generally wedge shaped to best accommodate it's location under and attached to the front support beam 101 and related handle assembly 105 . The reservoir 107 may be made from a clear, opaque, or translucent plastic such that the contents of the reservoir, and their depletion level, can be clearly seen by the user. The shape of the reservoir 107 may also vary along a vertical dimension such that there is additional ability to accommodate cleaning solution toward the bottom area of the reservoir 107 . A reservoir cap 109 can also be seen in FIG. 1 attached to the side (vertical wall) of the reservoir 107 . The placement of the reservoir cap 109 may vary, with some embodiments of the present invention placing the reservoir cap on the top or bottom horizontal surfaces of the reservoir 107 . The reservoir cap 109 may also be placed at an angle to any side by appropriate modification of the shape of the reservoir through tooling and related computer aided design (CAD). Further, the reservoir wall where the reservoir cap 109 is placed may protrude outward past the reservoir cap 109 in order to accommodate more cleaning solution and further to provide a more positive area for the reservoir cap to be situated.
[0040] Under the handle assembly 105 can also be seen a pump actuator lever assembly 111 that can be gripped and moved by a user to in turn move and actuate a pump that moves the cleaning solution or similar liquid from the reservoir 107 and out a nozzle (such details to be later described with the assistance of subsequent figures). The pump actuator lever assembly 111 may, in some embodiments of the present invention, be bent or angled such that a portion of the pump actuator lever assembly 111 is generally parallel to the handle (although variations on such parallel precision may be a matter of design choice, and a curved or otherwise non-parallel pump actuator lever assembly portion may be employed). The pump actuator lever assembly 111 also contains further structural components that will be further depicted and described by way of FIG. 12 .
[0041] As can also be seen in FIG. 1 , a pad 115 can be seen removably attached to the pad substrate 113 . The pad 115 can be replaced when worn, or when a different style cleaning pad is desired due to the nature of the cleaning task. The pad substrate 113 may be curved in some embodiments to provide a better overall cleaning form. The pad substrate 113 may also comprise slots completely through the pad substrate, and may also comprise slots that are only partially through the thickness of the pad substrate 113 . These various slots may be fashioned singularly, or may alternate such that the fully through slots and the partially through slots are adjacent each other in an alternating arrangement. In some embodiments of the present invention, the pad substrate 113 may be flexible or semi-flexible due to variables such as choice of material, thickness of material, number of slots, and the like. As will be further seen in subsequent figures, the pad substrate 113 is attached to the handle assembly 105 and a pad substrate strut and pad substrate retention fixture may further be employed to facilitate structural attachment of the handle to the substrate and related bristles. Such further details can be seen by way of example in FIG. 13 .
[0042] FIG. 2 is a rotated perspective view of the dispensing pad cleaner that clearly shows the dispensing nozzle 201 . The dispensing nozzle 201 is directed toward the leading edge or cleaning surface of the dispensing pad cleaner 100 in such a way that cleaning solution or similar liquid is deposited on the surface to be cleaned. The user may chose to dispense the cleaning solution or liquid while scrubbing with the dispensing pad cleaner 100 , or may lift the dispensing pad cleaner 100 away from the cleaning surface and direct the dispensing nozzle 201 at an area where the cleaning solution is to be applied. In this manner, the user can carry the dispensing pad cleaner 100 without the need to carry and pick up a cleaning device and cleaning solution dispensing bottle separately. Such convenience not only saves time, but through the precise application of cleaning solution also saves unnecessary consumption of cleaning solution during a cleaning task. In some embodiments of the present invention, the dispensing nozzle 201 is adjustable to change the spray pattern and/or delivery volume. The adjustment may be made by rotation of the nozzle, insertion of a screwdriver blade and subsequent rotation of the nozzle, or the like.
[0043] The reservoir cap 109 can also be seen in FIG. 2 as having a grip for ease of rotation and removal. The grip may be a longitudinal span, a knob, a point, knurls, other geometries, or simply the reservoir cap itself. Also seen is a vent hole that is coupled with a taper valve as seen in FIG. 9 .
[0044] FIG. 3 is a rear plan view of the dispensing pad cleaner where another perspective of the handle assembly 105 can be seen.
[0045] FIG. 4 is a front plan view of the dispensing pad cleaner showing clearly the placement of the dispensing nozzle 201 . As previously stated, the nozzle may be adjustable and further may be directional.
[0046] FIG. 5 is a top plan view of the dispensing pad cleaner. The flared bottom of the reservoir and the placement of the reservoir under the handle can be seen. The front support beam 101 of the handle assembly 105 is seen to be progressively larger than the handle itself in this exemplary embodiment. This larger size provides not only structural rigidity, but also accommodates internal placement of the pump, as shown in FIG. 9 .
[0047] FIG. 6 is a bottom plan view of the dispensing pad cleaner. The texture of the woven pad material of the pad 115 can be seen.
[0048] FIG. 7 is a side plan view of the dispensing pad cleaner that further shows the pump actuator lever and the angle thereof. Placement of the reservoir 107 in relation to the handle assembly 105 can also be seen as well as the exemplary slots or cuts in the pad substrate 113 .
[0049] FIG. 8 is a perspective view of the dispensing pad cleaner showing the cleaning pad removed. The way in which the cleaning pad 115 is attached to the dispensing pad cleaner can be clearly seen.
[0050] FIG. 9 is an exploded view of the dispensing pad cleaner. A handle overlay 901 can be seen as an optional item to provide comfort to the user, as the handle overlay is made from a soft durometer material, and may cover the entire handle or a portion thereof. A pump 903 can also be seen that provides fluid communication and fluid delivery between the reservoir 107 and the dispensing nozzle 201 that is depicted in FIG. 2 . The reservoir 107 has an opening or hole that is in turn connected to the pump 903 for the entry and subsequent expulsion of liquid previously contained in the reservoir 107 . The pump 903 may be any form of mechanical pump including a piston actuated or diaphragm style pump. In FIG. 9 , the pump 903 is mechanically coupled to the pump actuator lever assembly 111 by way of a cam feature that provides translational force from the lever piece through a curved cam structure and into a linear drive of the pump 903 where the linear drive includes a stem or similar surface to receive the force from the cam and transfer it to a piston or fluid moving arrangement within the pump to force liquid from the reservoir 107 and out the dispensing nozzle 201 with force sufficient to broadcast or spray the liquid onto a surface to be cleaned.
[0051] A gasket seal 907 can also be seen, and provides a liquid tight seal when the reservoir cap 109 is properly attached to the reservoir 107 . The gasket seal 907 may be a flat annular seal that is retained by a lip or recess on the reservoir cap itself, or may be an O-ring or the like. The gasket seal may be made from any soft durometer material suitable for liquid tight sealing, such as rubber, silicone rubber, various expanded or closed cell synthetic materials, cork, or the like. Also, a taper valve 905 can be seen that provides for replacement air into the reservoir 107 as liquid is being dispensed. FIG. 10 shows a close up view of this taper valve. The taper valve 905 brings two edges of material into close contact such that in one direction the edges are tight and in the other direction the edges are loose to allow for the passage of air while excluding the entry of liquid in an opposite direction. The taper valve 905 uses edges that are tapered or angled toward each other to accomplish this objective, and allows the reservoir cap 109 to be placed on a vertical wall of the reservoir 107 without leaking.
[0052] In some embodiments of the present invention the pump 903 is an electrically driven pump that is actuated through a lever, button or switch that contains electrical contacts.
[0053] FIG. 10 depicts a taper valve 905 of the reservoir cap. As previously described, the taper valve 905 is attached to a protrusion and opening on the reservoir cap 109 on the inward facing portion of the reservoir cap 109 . The angled or tapered surfaces of the soft durometer material of the taper valve provide a liquid seal in one direction while allowing make up air to enter the reservoir 107 in the other direction.
[0054] FIG. 11 depicts an engagement feature 1101 of the reservoir cap. This engagement feature may be a protrusion or recess that couples and locks with an opposing feature on the reservoir 107 along the surface where the reservoir cap 109 attaches to the reservoir 107 .
[0055] FIG. 12 depicts a pump actuator lever assembly 111 of the dispensing pad cleaner. A lever 1201 can be seen with a flattened or otherwise ergonomic surface to allow interaction by a user. Such interaction includes repeated movement of the lever 1201 to drive the pump 903 (see FIG. 9 ) and expel liquid from the dispensing nozzle 201 (see FIG. 2 ). A pump engagement cam 1203 can also be seen mechanically coupled or formed with the lever 1201 . The pump engagement cam 1203 provides translational force from the lever 201 through a cam 1203 and into a linear drive of the pump 903 where the linear drive includes a stem or similar surface to receive the force from the cam 1203 and transfer it to a piston or fluid moving arrangement within the pump to force liquid from the reservoir 107 and out the dispensing nozzle 201 with force sufficient to broadcast or spray the liquid onto a surface to be cleaned. The pump engagement cam 1203 may be curved or angled to facilitate proper interaction between the lever 1201 and the pump 903 as seen in FIG. 9 . To allow the pump actuator lever assembly 111 to pivot or hinge repeatedly in order to drive the pump, a first hinge pin 1205 and a second hinge pin 1207 can be seen protruding from the pump actuator lever assembly 111 at a suitable location such that recesses or similar features in the dispensing pad cleaner handle assembly 105 are able to receive and interact with the hinge pins such that movement occurs that is sufficient and adequate to drive the pump.
[0056] FIG. 13 depicts a handle assembly 105 of the dispensing pad cleaner. The various features within the handle assembly to accommodate the pump 903 (not shown in FIG. 13 ) can be seen. In addition, a pad substrate strut 1301 can be seen that has a generally flat appearance to accommodate attachment of the pad substrate to the handle assembly 105 . A pad substrate retention fixture 1303 can be seen where the pad substrate is mechanically fastened to the pad substrate strut 1301 and related handle assembly 105 . In some embodiments of the present invention, the pad substrate strut 1301 is curved to conform to a pad substrate.
[0057] FIG. 14 depicts a handle overlay 901 of the dispensing pad cleaner. As previously stated, the handle overlay is made from a soft durometer material to provide a comfortable and secure grip for the user.
[0058] FIG. 15 depicts a handle half 1501 of the dispensing pad cleaner. This handle half 1501 mates with the handle assembly 105 to form a handle that also incorporates the pump within the two pieces. Fastening features and pump retention features can be clearly seen in FIG. 15 . As the two halves are joined together, the reservoir 107 , as further depicted in FIG. 16 , is retained by mechanical means such as a reservoir attachment protrusion 1601 that provides a protrusion, in one embodiment a linear protrusion, that can be captured and retained by the handle half 1501 and handle assembly 105 when formed or attached together. A reservoir fill opening 1603 can also be seen protruding from the reservoir 107 with at least one reservoir engagement feature 1605 that may include a slot, recess, or slot with an angled (such as right angled) opening in the reservoir fill opening 1603 to allow for engagement and retention of the reservoir cap 109 (not shown in FIG. 16 ).
[0059] FIG. 17 is a side view of a pad substrate assembly 113 of the dispensing pad cleaner. A front substrate strut attachment feature 1701 can be seen along with a rear substrate strut attachment feature 1705 . The attachment features may be protrusions or recesses with mating geometries to allow attachment of the pad substrate 113 to the handle assembly 105 . In addition, a first pad hook 1703 can be seen as well as a second pad hook 1707 . The pad hooks engage with pad retention slots (see FIGS. 1 and 8 ) to secure the pad to the pad substrate. The pad hooks may be curved and flare outward to provide secure retention of the pad to the pad substrate while allowing for ease of removal and replacement.
[0060] FIG. 18 is a plan view of the pad substrate assembly 113 of the dispensing pad cleaner showing side cuts 1801 that alternate with full transverse cuts. In some embodiments of the present invention, the substrate is curved or otherwise retained in a curved position. The perspective view of FIG. 19 better shows the curved substrate embodiment and also further depicts the attachment features 1701 and 1705 as well as the first pad hook 1703 and the second pad hook 1705 . While the substrate may be curved, downward pressure by the user may straighten out the substrate, providing improved cleaning force.
[0061] FIG. 20 is a perspective view of the pump 903 of the dispensing pad cleaner. Various embodiments of the present invention may employ various types of pumps. In this example, a linear piston style pump is depicted. A pump piston stem 2001 can be seen that provides a surface for the pump engagement cam to move when the pump actuator lever is moved. The pump piston stem 2001 is in turn connected to the pump piston (not show in FIG. 20 , see FIG. 21 ). A pump cylinder 2003 houses and seals the pump piston and a pump body 2005 provides fluid communication between the pump cylinder 2003 and the pump intake 2007 and the pump discharge 2009 . For both the pump intake 2007 and the pump discharge 2009 fittings can be seen to allow attachment to a hose, conduit, or the like. To show the inner workings of the exemplary pump 903 , an exploded view of the pump can be seen in FIG. 21 . A spring 2101 can be seen to return the piston 2103 to a given linear position in the cylinder. The piston 2103 also has seals to provide a liquid tight seal between the piston and the cylinder, thus allowing for movement and spray of the cleaning solution placed within the reservoir of the dispensing pad cleaner. A piston spring 2105 can also be seen to provide return force to the piston 2103 as it travels through the cylinder 2003 . Seals such as O-rings and gaskets are used as necessary to provide for a liquid tight seal and associated pressurization and expulsion of cleaning solution by the pump 903 .
[0062] To use the dispensing pad cleaner, cleaning solution or a similar liquid is placed in the reservoir and the reservoir then appropriately capped. A pump actuator lever is squeezed and released repeatedly, driving the liquid from the reservoir and through a dispensing nozzle. The dispensing pad cleaner is positioned such that the expelled liquid is deposited on a surface to be cleaned, and the dispensing pad cleaner is used to scrub and subsequently clean the surface. The dispensing pad cleaner provides a novel arrangement for dispensing cleaning solution or similar liquid in an efficient and cost effective manner, something heretofore not possible with separate dispensing bottles and cleaning devices.
[0063] It is, therefore, apparent that there has been provided, in accordance with the various objects of the present invention, a dispensing pad cleaner. While the various objects of this invention have been described in conjunction with preferred embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of this specification, claims and the attached drawings. | A dispensing pad cleaner is disclosed having a novel integrated dispensing system for delivering cleaning solutions and similar liquids to a surface to be cleaned. A removable cleaning pad coupled to a flexible pad substrate is also provided. The dispensing system has a reservoir for liquid retention that is coupled to the dispensing pad cleaner. An integral pump dispenses the liquid from the reservoir and through a nozzle to a surface to be cleaned. The pump is actuated from a lever that is depressed by a user, at times repeatedly, to facilitate pumping of the liquid onto a surface to be cleaned by scrubbing action of the dispensing pad cleaner. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
None.
FIELD OF THE INVENTION
The invention is in the field of motor driven, bubble producing toys.
BACKGROUND OF THE INVENTION
Motor driven, bubble producing toys have been around for many years. Typically, such toys have a bubble solution reservoir, a motive power source, for example, a battery, a motor, a pump, a bubble solution feed tube, and a bubble wand. Exemplary patents and patent publications include U.S. Pat. Nos. 4,764,141; 5,613,890; 6,200,184; 7,056,182; 7,059,930, 5,498,191; 5,975,358; 6,663,464; 7,470,165; 5,520,564; 6,024,632; 7,056,182; United States Patent Publication Nos. 2002/0061697; 2002/0090878; 2005/0148276; 2007/0032163; 2012/214378 and PCT Patent Publication No. WO2008/011346.
These bubble producing toys include those in which a bubble ring is dipped into bubble solution and then exposed to an air stream and those in which a wiper, typically a wire, travels across an bubble aperture coating it with bubble solution which is then exposed to an air stream. Both of these mechanisms have drawbacks. In the former case, the dipping ring device tends to lose solution readily or fail to form film consistently so the toy works intermittently. In the latter case, the wire can easily be bent or broken and the toy rendered unusable.
Accordingly, there is a need for an improved bubble producing mechanism that can be used with motor driven bubble producing toys. One such improved mechanism is provided by the invention.
SUMMARY OF THE INVENTION
The invention provides an improved mechanism for producing bubbles in a motor driven bubble producing toy. The mechanism is a bubble generating assembly that automatically forms a bubble film around a bubble wand without the need to dip the bubble wand into the bubble solution reservoir or to wipe the bubble wand with a wiper blade. In the improved mechanism of the invention, a bubble ring, a flat hollow disc that is either dipped in bubble solution or wiped with a wiper to form a film across the hollow portion of the ring is not employed.
The improved mechanism is a bubble wand formed with a moving semi-circular or arcuately shaped, wand portion and a stationary, semi-circular or arcuately shaped, wand portion. The arcuate wand portions are connected to each other by means of a pair of integral hinges located at each of the ends of the semi-circular wands. The pair of hinges permit the moving wand portion to move in relation to the stationary wand portion, from a closed and superposed position over the stationary wand portion to an open, film-forming, position at an angular orientation to the stationary wand portion. The arrangement and orientation of the two wand portions are similar to a jaw, and move in much the same manner. Besides being semi-circular in general shape, the two wand portions may otherwise resemble a typical bubble wand, i.e., with a width that is somewhat greater than the height and with each surface being substantially planer in general aspect.
The opposed surfaces of the moving and stationary wand portions have regularly spaced grooves and ridges or ribs, with the heights of the ribs being consistent throughout, that hold the bubble solution against the wand portion and assist in film formation when the moving wand portion is in it open, film-forming, position as is typical of bubble wands and known in the art. Preferably the wand portions are made of a rigid plastic material and the pair of hinges is formed by means of a pair of integral posts disposed on one of either the moving or stationary wand portions and a pair of post-receiving bores formed in the other wand portion. For example, two integral posts, one at each end, may be formed in the semi-circularly shaped moving wand portion and two bores, one at each end, may be formed in the semi-circularly shaped stationary want portion, or vice versa. Alternatively, the moving wand portion may be formed with one bore and one post and the stationary wand portion may be formed with a mating bore and a mating post. The precise arrangement is not critical. What is critical is that the two wand portions are hinged together at their ends to form a jaw-like structure that can open and close. While the preferred shape of the two wand portions is substantially semi-circular or arcuate, other shapes may also work. For example, a half-ovoid shape or an angled shape such as a half-square or half-rectangle may be employed. Regardless of shape, the two wand portions should be mirror images of each other so as to be superposable.
The invention is exemplified in the following detailed description taken together with the drawings as described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary, motor driven, bubble producing toy in which the invention is embodied. The improved bubble wand mechanism of the invention is shown in its closed position.
FIG. 2 is front plan view of the toy illustrated in FIG. 1 , with the improved bubble wand mechanism of the invention shown in its open, bubble generating, position.
FIGS. 3A and 3B are perspective views of the upper portion of the toy, showing the improved bubble wand in the closed position ( FIG. 3A ) and the open, bubble generating position ( FIG. 3B ).
FIG. 3C is a perspective view of the hood portion of the toy.
FIG. 4 is an exploded view illustrating the internal components of the motor fan pump assembly and the integrated electrical activation switch of the exemplary toy embodying of the invention.
FIG. 5 is an exploded view of the lower portion of the toy showing the arrangement of the motor, fans and actuation assembly.
FIG. 6 is a perspective view of FIG. 5 .
DETAILED DESCRIPTION
The figures illustrate how the improved bubble wand of the invention can be included in a motor driven bubble producing toy. In FIGS. 1 and 2 , there is shown a motor driven bubble producing toy in the general shape of a figurine with a head and a body. The toy is composed of a motor assembly 30 , a fan assembly 40 , and a pump assembly 50 disposed in the body of the figurine and a bubble making assembly 20 disposed in the head of the figurine. Each of these assemblies will be described in detail infra. The body of the toy has a bubble solution reservoir, 10 , for retaining bubble solution and a removable reservoir cap, 19 . Removing the cap allows the user to add bubble solution to the reservoir. Connected to the reservoir through cap 11 is a bubble solution feed tube, 12 , and a bubble solution return tube, 13 . Feed tube 12 extends from the reservoir through the body of the toy and terminates at its other end in a feed tube receptor situated in the bubble making assembly as will be described infra. In FIG. 1 , the improved bubble wand mechanism of the invention is illustrated in its closed position and in FIG. 2 , it is illustrated in its open, bubble making, position. Bubble solution return tube 13 is also provided, extending from bubble solution outlet 14 (see FIGS. 1 and 4 ) in the bottom of bubble making assembly 20 into solution reservoir 10 through cap 11 . It captures excess bubble solution and returns it to the reservoir.
FIGS. 3 and 4 illustrate the improved bubble want of the invention in detail in its closed position ( FIG. 3A ), its open position ( FIG. 3B ), with a hood for a toy figurine with a hooded head embodiment ( FIG. 3C ), and in an exploded view ( FIG. 4 ). In FIGS. 3A and 3B , moving wand portion 21 and stationary wand portion 26 are formed with regularly spaced apart ribs 22 that assist in film formation by spreading the solution around the wand by capillary action. Moving wand portion 21 and stationary wand portion 26 are demountably fastened to each other by means of an integral hinge composed of a pair of hinge posts 25 at the ends of moving wand portion 21 and a pair mating bores at the ends of stationary wand portion 26 . This hinge post and bore arrangement makes for a very simple hinge and enables the bubble wand to open and close in a jaw-like manner. The wand is shown closed in FIG. 3A and open in FIG. 3B . As is typical of bubble wands, the two arcuate wand portions 21 and 26 are substantially planar in aspect, having a width greater than the sides and formed with a series of spaced apart ribs 22 on their front and back surfaces. Also part of the assembly, bubble wand actuator 23 is positioned mid-way between the ends of moving wand portion 21 and projects from the outer side of the arcuate wand portion axially and in the same plane. Actuator 23 is formed with bubble feed tube receptor 24 , into which bubble solution feed tube 12 terminates. Receptor 24 is formed with an aperture to permit the solution from the bubble feed tube to enter the receptor and drip onto wand portion 21 . Stationary wand portion 26 is stabilized in the head structure 65 of the toy by its connection to wand assembly body 29 , which is secured in place by means of screw boss pair 66 . The assembly is provided with a manually movable hood, 60 , (see FIG. 3C ) that is disposed on the head structure 65 and is formed of two pieces, head front 62 and head back 61 . Head back 61 is formed with a pair of cam axles 64 and a pair of mated openings 63 in the hood, one on each side thereof. Hood 62 is thereby movable from a closed position covering the bubble producing wand assembly and an open position that exposed the wand assembly to the environment. The front portion of hood 62 is formed so as to engage with actuator 23 when the hood is manually moved to its open position. This engagement moves the moving wand portion from its closed position to it open position and causes spring arm 31 to depress actuating the motor, and thereby the fan and the pump as will be described below.
Referring now to FIGS. 5 and 6 , the exemplified motorized bubble producing figurine toy is provided with fan assembly 40 composed of bladed air fan, 42 , that is disposed within fan housing 43 and connected to the motor 31 via fan mount 32 as can best be seen in FIG. 5 . Motor 31 is provided with pinion gear 33 at its end opposite fan mount 32 . Electric switch 38 is connected to motor 31 and to spring arm 34 by means of compression spring 35 (see FIGS. 5 and 6 ). A pump assembly, 50 , including gear 36 and pump roller 37 is provided to pump bubble solution from the reservoir to the wand assembly via feed tube 12 . As part of the fan assembly, an air feed tube, 44 , which extends from and is formed as part of the fan housing is provided. Air feed tube 44 directs the moving air created by the turning fan blades through the tube and into air aperture 49 disposed and arranged behind the bubble wand assembly in the upper portion of the toy. When electric switch 38 is tripped to start the battery driven motor 21 , the motor turns fan 42 forcing air into air aperture 12 and, simultaneously, the motor pinion gear 16 turns pump gear 32 and pump roller 33 , which siphons bubble solution from the reservoir through the feed tube, 17 , into the bubble solution feed tube receptor and onto the grooved surface of moving wand portion 13 .
FIG. 5 shows an exploded view of the fan, pump and motor assemblies of the exemplified toy. Motor 31 is connected to fan 42 and to pump assembly 50 by means of fan mount 32 and pinion gear 33 respectively. Fan 42 is disposed within fan housing 43 , which is formed with projecting air feed tube 44 that extends into the bubble making assembly in the head of the figurine, terminating in air aperture 49 behind the bubble wand assembly composed of hingably connected moving and stationary wands 21 and 26 . In the motor assembly 30 , pinion gear 33 engages with drive gear 36 , which in turn engages with pump roller gear 37 in the pump assembly. When motor 31 activated by switch 38 , pinion gear 33 turns gear 36 , turning pump roller gear 37 causing bubble solution in the reservoir to siphon through bubble feed tube 12 into feed tube receptor 24 and onto moving wand 21 as will be described. Cover plate 47 is provided to protect the pump assembly.
As part of the motor assembly, spring arm 34 is disposed within the body of the figurine between electric switch 38 , which is operatively connected to motor 31 , and cam axle 64 . Cam axle 64 is rotated about an axis when hood 60 is opened. This rotation drives spring arm 34 downward and the bottom of spring arm 34 makes contact with electric switch 38 activating it and the motor thereby. When hood 60 is released, compression spring 35 , which is mounted between electric switch 38 and spring arm 34 , moves the latter upward and out of contact with the switch, thereby turning off the motor, fan and pump. When the switch is engaged with the swing arm, the motor assembly spins the pinion gear, rotating the drive gear, which in turn rotates the pump roller gear. The pump roller gear is provided with two integral lobes, 39 , disposed in opposed relation to each other on the back side of the roller gear. (Only one of the lobes can be seen in FIG. 5 .) As the roller gear rotates, the lobes are forced against the bubble solution feed tube 12 . This action provides a pulsing pressure, and pumps the solution out of the reservoir into the feed to and out the aperture of the receptor, 24 , disposed on the moving wand. Simultaneously, the fan forces air through the projecting air feed tube 44 that extends into the bubble making assembly into the head of the figurine and out air aperture 49 behind the bubble wand assembly. Thus, when hood 62 is opened, bubble wand actuator 23 opens the bubble wand assembly and, simultaneously, the rotation of cam axle 64 engages spring arm 34 to contact switch 38 to turn on the motor, fan and pump to bring air and bubble solution to the wand assembly.
The bubble wand assembly of the invention finds use in any motor driven bubble toy. The foregoing figurine is merely exemplary and should not be limiting. As is known, the hood actuating assembly could readily be replaced with a trigger mechanism actuating opening and closing of the arcuate bubble wand portions, the motor, pump and fan via a series of levers and the figuring replaced with an alternative structure. Also, arrangements of the motor, pump, and fan assemblies different from that describe herein are possible as the skilled artisan will appreciate. All referenced publications are hereby incorporated by reference for the substance of what they disclose. | An improved bubble wand assembly for a motor driven, bubble producing toy is provided. The wand assembly includes a moving substantially semi-circular, wand portion and a stationary, substantially semi-circular, wand portion, the moving and stationary wand portions being hingably connected to each other at the ends thereof to permit the moving wand portion to move in relation to the stationary wand portion from a closed and superposed position over the stationary wand portion to an open, film-forming, position at an angular orientation to the stationary wand portion. | 0 |
TECHNICAL FIELD
The present invention relates to codeinone reductase from alkaloid poppy plants, the polynucleotides encoding the enzyme and to production of alkaloids from transformed poppy plants.
BACKGROUND
The search for useful drugs of defined structure from plants began with the isolation of morphine from dried latex, or opium, of the opium poppy Papaver somniferum in 1806 (Sertürner). The narcotic analgesic morphine and the antitussive and narcotic analgesic codeine, the antitussive and apoptosis inducer noscapine (Ye et al., 1998), and the vasodilator papaverine are currently the most important physiologically active alkaloids from opium poppy. Of these four alkaloids, only papaverine is prepared by total chemical synthesis for commercial purposes. Opium poppy, therefore, serves as one of the most important renewable resources for pharmaceutical alkaloids. Per annum, 90–95% of the approximately 160 tons of morphine that are purified are chemically methylated to codeine, which is then used either directly or is further converted to a variety of derivatives such as dihydrocodeinone and 14-hydroxydihydrocodeinone that find use as antitussives and analgesics (Kutchan, 1998). The illicit production of morphine for acetylation to heroin is unfortunately almost ten times that amount, more than 1200 tons per year (Zenk, 1994).
The enzymatic synthesis of morphine in opium poppy has been almost completely elucidated by M. H. Zenk and coworkers and is summarized by Kutchan (1998). Opium poppy produces more than 100 different alkaloids that are derived from the amino acid L-tyrosine and have the tetrahydrobenzylisoquinoline alkaloid, (S)-reticuline, as a common intermediate. There are three NADPH-dependent reductases involved in the conversion of (S)-reticuline to morphine. (S)-Reticuline must first be converted to (R)-reticuline before the phenanthrene ring with the correct stereochemistry at C-13 can be formed. The inversion of stereochemistry at C-1 of (S)-reticuline occurs by oxidation to the 1.2-dehydroreticulinium ion followed by stereospecific reduction to the R-epimer by 1.2-dehydroreticulinium ion reductase [EC 1.5.1.27] (De-Eknamkul and Zenk, 1992). The second reduction occurs after formation of the phenanthrine nucleus with stereo specific reduction of salutaridine to salutaridinol by salutaridine reductase [EC 1.1.1.248] (Gerardy and Zenk, 1993). The third reduction is the penultimate step in the biosynthetic pathway to morphine, the reduction of codeinone to codeine by codeinone reductase [EC 1.1.1.2471] ( FIG. 1 ; Lenz and Zenk, 1995a,b). The substrate for codeinone reductase, codeinone, exists in an equilibrium with its positional isomer neopinone. In vitro, as codeinone is reduced, this equilibrium is continually driven from neopinone towards codeinone until the substrates are depleted (Gollwitzer et al., 1993). Each of the known enzymes of morphine biosynthesis has been detected in both P. somniferum plants and cell suspension culture, yet plant cell cultures have never been shown to accumulate morphine (Kutchan, 1998). Sequences of genes encoding cytochrome P450 reductases have been published in PCT/AU98/000705 which is hereby incorporated by reference.
To date, no other genes specific to morphine biosynthesis in opium poppy have been isolated. Tyrosine/dopa decarboxylase has been investigated at the molecular genetic level, but is involved in multiple biochemical processes in this plant (Facchini and De Luca, 1994). Morphine, along with the chemotherapeutic agents vincristine, vinblastine and camptothecin, is one of the most important alkaloids commercially isolated from medicinal plants. Isolation of the genes of morphine biosynthesis would facilitate metabolic engineering of opium poppy to produce plants with specific patterns of alkaloids and could ultimately lead to an understanding of the inability of plant cell cultures to accumulate morphine.
It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.
SUMMARY OF THE INVENTION
The narcotic analgesic morphine is the major alkaloid of the opium poppy Papaver somniferum . Its biosynthetic precursor codeine is currently the most widely used and effective antitussive agent. Along the morphine biosynthetic pathway in opium poppy, codeinone reductase catalyzes the NADPH-dependent reduction of codeinone to codeine. At least 10 codeinone reductase alleles are present in the genome of the poppy Papaver somniferum . Isolation, characterization and functional expression of four of the 10 genes encoding codeinone reductase as described herewith enables methods for controlling alkaloid production in opium poppy plants and cultures by providing a target for genetic manipulation.
Thus, according to a first aspect, there is provided an isolated and purified polynucleotide or a variant, fragment or analog thereof, encoding a codeinone reductase enzyme from an alkaloid poppy plant.
The polynucleotide may be selected from the group consisting of genomic DNA (gDNA), cDNA, or synthetic DNA. Preferred polynucleotides are selected from (a) the polynucleotide sequences shown in FIGS: 10 to 15; (b) the polynucleotide sequences which hybridize under stringent conditions to the complementary sequences of (a); and (c) polynucleotide sequences which are degenerate to polynucleotide sequences of (a) or (b). It will be understood however that the sequences may be expressed in the absence of the native leader sequences or any of the 5′ or 3′ untranslated regions of the polynucleotide. Such regions of the polynucleotide may be replaced with exogenous control/regulatory sequences in order to optimise/enhance expression of the sequence in an expression system.
The preferred alkaloid-producing poppy plant is Papaver somniferum.
It will also be understood that analogues and variants of the polynucleotide encoding a codeinone reductase from alkaloid poppy plants fall within the scope of the present invention. Such variants will still encode an enzyme with codeinone reductase properties and may include codon substitutions or modifications which do not alter the amino acid encoded by the codon but which enable efficient expression of the polynucleotide encoding codeinone reductase enzyme in a chosen expression system. Other variants may be naturally occurring, for example allelic variants or isoforms.
According to a second aspect there is provided an isolated and purified polynucleotide, or a variant, analog or fragment thereof, which codes for prokaryotic or eukaryotic expression of a codeinone reductase enzyme from an alkaloid poppy plant, wherein the polynucleotide is expressed in an environment selected from the group consisting of the extracellular environment, an intracellular membranous compartment, intracellular cytoplasmic compartment or combinations thereof.
The polynucleotide encoding a codeinone reductase may be coupled to another nucleotide sequence which would assist in directing the expression of the reductase with respect to a particular cellular compartment or the extracellular environment.
According to a third aspect there is provided an isolated and purified polynucleotide which is complementary to all or part of the sequence of a polypeptide according to the first aspect.
Such complementary polynucleotides are useful in the present invention as probes and primers, as antisense agents or may be used in the design of other suppressive agents such as ribozymes and the like.
According to a fourth aspect there is provided a recombinant DNA construct comprising the polynucleotide according to any one of the first to third aspects.
Preferably the recombinant DNA construct is a viral or plasmid vector. Such a vector may direct prokaryotic or eukaryotic expression of the polynucleotide encoding a codeinone reductase or it may prevent or reduce its expression. The vector may also be selected from pCAL-c, pGEM-T or pFastBac1. Preferably the promoter used to control expression of the codeinone reductase gene is selected from nos, cauliflower mosaic virus or subterranean clover mosaic virus.
According to a fifth aspect there is provided an isolated and purified codeinone reductase enzyme, being a product of prokaryotic or eukaryotic expression of the polynucleotide of any one of first to third aspects or a DNA construct of the fourth aspect.
The codeinone reductase may be expressed in and by a variety of eukaryotic and prokaryotic cells and organisms, including bacteria, yeasts, insect cells, mammalian and other vertebrate cells, or plant cells. Preferably the expression system is a plant expression system and even more preferred is an alkaloid poppy plant. A suitable alkaloid poppy plant is Papaver somniferum.
Variants of the codeinone reductase enzyme which incorporate amino acid deletions, substitutions, additions or combinations thereof, are also contemplated. The variants can be advantageously prepared by introducing appropriate codon mutations, deletions, insertions or combinations thereof, into the polynucleotide encoding the codeinone reductase enzyme. Such variants will retain the properties of the codeinone reductase enzyme, either in vivo or in vitro, and may have improved properties. Other valiants may be naturally occurring, for example allelic variants or isoforms.
For expression of codeinone reductase activity, a fragment of the polynucleotide encoding a codeinone reductase may be employed, such fragment encoding functionally relevant regions, motifs or domains of the reductase protein. Similarly, fragments of the codeinone reductase enzyme resulting from the recombinant expression of the polynucleotide may be used. Functionally important domains of codeinone reductase may be represented by individual exons or may be identified as being highly conserved regions of the protein molecule. Those parts of the codeinone reductase which are not highly conserved may have important functional properties in a particular expression system.
According to a sixth aspect there is provided a cell transformed or transfected with a polynucleotide according to any one of the first to third aspects or a DNA construct according to the fourth aspect.
Cells which may be transfected or transformed with a polynucleotide encoding a codeinone reductase are bacterial, yeast, animal or plant cells. For preference the cells are plant cells. Even more preferred are cells from an alkaloid poppy plant, such as Papaver somniferum.
According to the seventh aspect, there is provided a callus transformed or transfected with a polynucleotide according to any one of the first to third aspects or a DNA construct according to the fourth aspect.
According to the eighth aspect, there is provided a plant transformed or transfected with a polynucleotide according to any one of the first or third aspects or a DNA construct according to the fourth aspect wherein the plant exhibits altered expression of the codeinone reductase enzyme. For preference, the altered expression manifests itself in overexpression of the codeinone reductase enzyme. However, reduced expression of codeinone reductase can also be achieved if the plant is transformed or transfected with a polynucleotide which is complementary to the polynucleotide encoding the reductase.
Even more preferably, the transformed or transfected plant is an alkaloid poppy plant, wherein the plant has a higher or different alkaloid content when compared to a plant which has not been so transformed or transfected.
Preferably the transformed or transfected plants having higher or different alkaloid content are Papaver somniferum.
According to the ninth aspect, there is provided a method for preparing plants which overexpress a codeinone reductase enzyme, comprising transfecting or transforming a plant cell, a plant part or a plant, with the polynucleotide according to any one of the first to third aspects or a DNA construct according to the fourth aspect.
Preferably the plant overexpressing codeinone reductase is an alkaloid poppy plant and most preferably the poppy plant is Papaver somniferum . Suitable promoters to control the expression of the codeinone reductase gene may be derived from for example nos, cauliflower mosaic virus or subterranean clover mosaic virus. Other virus promoters may also be suitable. Further, the use of the endogenous promoter may also be appropriate in certain circumstances. Such a promoter may be co-isolated with the gDNA encoding the codeinone reductase enzyme.
According to the tenth aspect, there is provided a method of altering the yield or type of alkaloid in a plant comprising transforming or transfecting a plant cell, a plant part or a plant with a polynucleotide, or a variant, analog or fragment thereof, encoding a codeinone reductase enzyme, or with a polynucleotide which binds under stringent conditions to the polynucleotide encoding the enzyme.
According to the eleventh aspect, there is provided a method of increasing the yield of alkaloid in a plant comprising transforming or transfecting a plant cell, a plant part or a plant with a polynucleotide, or a variant, analog or fragment thereof, encoding a codeinone reductase enzyme wherein the enzyme is overexpressed in the plant.
According to the twelfth aspect, there is provided a method of altering type or blend of alkaloid in a plant comprising transforming or transfecting a plant cell, a plant part or a plant with a polynucleotide or a variant, analog or fragment thereof, encoding a codeinone reductase enzyme or with a polynucleotide which binds under stringent conditions to the polynucleotide encoding said enzyme.
According to the thirteenth aspect, there is provided a stand of stably reproducing alkaloid poppies transformed or transfected with a polynucleotide according to any one of the first to third aspects or a DNA construct according to the fourth aspect, having altered expression of the codeinone reductase enzyme.
According to the fourteenth aspect, there is provided a stand of stably reproducing alkaloid poppies transformed or transfected with a polynucleotide according to any one of the first to third aspects or a DNA construct according to the fourth aspect, having a higher or different alkaloid content when compared to a plant which has not been so transformed or transfected.
Preferably the stably reproducing alkaloid poppy is Papaver somniferum.
According to the fifteenth aspect, there is provided straw of stably reproducing poppies according to the fourteenth aspect having a higher or different alkaloid content when compared to the straw obtained from an alkaloid poppy which has not been transformed or transfected.
According to the sixteenth aspect, there is provided a concentrate of straw according to the fifteenth aspect having a higher or different alkaloid content when compared to the concentrate of straw obtained from an alkaloid poppy which has not been transformed or transfected.
According to the seventeenth aspect, there is provided an alkaloid when isolated from the straw according to the fifteenth aspect or the concentrate according to the sixteenth aspect. Preferably the alkaloid is selected from the group consisting of morphine, codeine, oripavine and thebaine.
According to the eighteenth aspect, there is provided a method for production of poppy plant alkaloids comprising the steps of;
a) harvesting capsules of an alkaloid poppy plant transformed or transfected with a polynucleotide according to any one of the first to third aspects, or a DNA construct according to the fourth aspect, to produce a straw where the poppy plant is such a plant that the straw has a higher or different alkaloid content when compared to the straw obtained from a poppy plant which has not been transformed or transfected; and
b) chemically extracting the alkaloids from the straw.
According to the nineteenth aspect, there is provided a method for the production of poppy alkaloids comprising the steps of;
a) collecting and drying the latex of the immature capsules of an alkaloid poppy plant transformed or transfected with a polynucleotide according to any one of the first to fourth aspects, to produce opium wherein the poppy plant is such a plant that the opium has a higher of different alkaloid content when compared to the opium obtained from a poppy plant which has not been transformed or transfected; and
b) chemically extracting the alkaloids from the opium.
For preference the alkaloid is morphine, codeine, oripavine or thebaine, but it will be understood that other intermediates in the alkaloid metabolic pathway are also within the scope of the present invention, as are mixtures of alkaloids.
According to a twentieth aspect, the invention provides the polynucleotide sequence encoding codeinone reductase comprised in microbial deposit No. 12737.
According to a twenty-first aspect, the invention provides the polynucleotide sequence encoding codeinone reductase comprised in microbial deposit No. 12738.
According to a twenty-second aspect, the invention provides the polynucleotide sequence encoding codeinone reductase comprised in microbial deposit No. 12739.
According to a twenty-third aspect, the invention provides the polynucleotide sequence encoding codeinone reductase comprised in microbial deposit No. 12740.
Unless the context clearly requires otherwise, throughout the description and the claims, the words ‘comprise’, ‘comprising’, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 . Biosynthetic pathway leading from S-Reticuline to morphine in the opium poppy, Papaver somniferum.
The reduction of codeinone to codeine by codeinone reductase drives the non-enzymatic equilibrium between neopinone and codeinone in a physiologically forward direction. The demethylation of thebaine and codeine are each thought to be catalyzed by cytochrome P450-dependent enzymes.
FIG. 2 . Partial amino acid sequences of native codeinone reductase. Peptide 3 is SEQ ID NO: 9, Peptide 7 is SEQ ID NO: 10, Peptide 14 is SEQ ID NO: 11, Peptide 16 is SEQ ID NO: 12, Peptide 17 is SEQ ID NO: 13, Peptide 25 is SEQ ID NO: 14, and Peptide 29 is SEQ ID NO: 15.
Codeinone reductase was purified to apparent electrophoretic homogeneity from cell suspension cultures of opium poppy and hydrolyzed with endoproteinase Lys-C. The resultant peptide mixture was resolved by HPLC and the amino acid sequences of seven peptides were obtained.
FIG. 3 . Amino acid sequence homology of codeinone reductase internal peptides.
Codeinone reductase peptides 3, 7, 14, 16, and 17 aligned with the reductase subunit of the 6′-deoxychalcone synthase complex from alfalfa (SEQ ID NO: 16), glycyrrhiza (SEQ ID NO: 17) and soybean (SEQ ID NO: 18) allowing the relative positioning of these internal peptides from opium poppy (SEQ ID NO: 19).
FIG. 4 . Amino acid sequence comparison of codeinone reductase isoforms.
The amino acid sequences derived from translation of the nucleotide sequences of cor1.1–1.4 (SEQ ID NOS. 26, 27, 28, and 29, respectively) as compared to the reductase subunit of the 6′-deoxychalcone synthase complex from soybean (SEQ ID NO: 18) indicate the very high sequence identity between isoforms (95–96%) and this reductase of phenylpropanoid metabolism (53%). The complete amino acid sequence of cor1.1 (SEQ ID NO: 26) is shown, but only those non-identical residues of the four subsequent sequences.
FIG. 5 . Genomic DNA gel blot analysis of the codeinone reductase gene family in opium poppy.
Genomic DNA isolated from opium poppy cell suspension cultures was hybridized to cor1.1 full-length cDNA and was visualized by phosphorimaging. The numbers following the restriction enzyme names indicate the number of recognition sites that occur within the cor1.1 reading frame. This high stringency Southern analysis indicates the presence of at least ten alleles in the opium poppy genome.
FIG. 6 . RNA gel blot analysis of distribution of codeinone reductase transcript in a mature opium poppy.
The gel blot was prepared from RNA isolated from leaf mid rib, lateral root and 12 cm of stem tissue directly beneath the receptacle of an opium poppy plant 2 days after petal fall. 50 μg of total RNA were loaded per gel lane. The RNA was hybridized to cor1.1 full length cDNA and was visualized by phosphorimagery.
FIG. 7 . SDS-PAGE analysis of fractions from the purification of codeinone reductase fusion protein from E. coli.
Codeinone reductase was expressed as a C-terminal fusion with a 25 amino acid calmodulin-binding peptide in E. coli BL21 (DE3)pLysS. Protein bands were visualized with coomassie brilliant blue R-250. Lane 1, 15 μg crude protein from an extract of E. coli BL21 (DE3)pLysS containing the codeinone reductase cDNA before IPTG induction; lane 2, 10 μg crude protein from an extract of E. coli BL21 (DE3)pLysS containing the codeinone reductase cDNA 3 h after IPTG induction; lane 3, 5 μg protein from the calmodulin affinity chromatography eluate after concentration using a Centriprep 30 column (Amicon); lane 4, Rainbow Marker protein standards (Amersham). Arrow indicates position of codeinone reductase fusion protein.
FIG. 8 . Chemical structures of alkaloids serving as substrates for codeinone reductase.
Of the twenty-six potential substrates tested, only seven were transformed by codeinone reductase. The names of the untransformed compounds are given in the Description of Preferred Embodiments. Codeinone is the physiological substrate for this enzyme in most, if not all, varieties of opium poppy. Morphinone also serves as a physiological substrate in Tasmanian varieties. The K m values provided for those seven substrates were determined for COR1.3.
FIG. 9 . Proposed alternative biosynthetic pathway leading from thebaine to morphine in opium poppies from Tasmania.
This alternative biosynthetic pathway was proposed after oripavine was discovered in Tasmanian varieties of opium poppy (Brochmann-Hanssen, 1984). Codeinone reductase from non-Tasmanian varieties can also catalyze the reduction of morphinone to morphine (Lenz and Zenk, 1995b). COR1.1–COR1.4 each catalyzed this reduction with equivalent specific activity. The demethylation of thebaine and codeine are thought to be catalyzed by cytochrome P450-dependent enzymes.
FIG. 10 . cDNA sequence of cor1.1. (SEQ ID NO: 20)
FIG. 11 . cDNA sequence of cor1.2. (SEQ ID NO: 21)
FIG. 12 . cDNA sequence of cor1.3. (SEQ ID NO: 22)
FIG. 13 . cDNA sequence of cor1.4. (SEQ ID NO: 23)
FIG. 14 . Partial cDNA sequence of cor1.5. (SEQ ID NO: 24)
FIG. 15 . Partial cDNA sequence of cor1.6. (SEQ ID NO: 25)
DESCRIPTION OF THE PREFERRED EMBODIMENTS
cDNas that encode codeinone reductase were isolated. Four full-length reading frames and two partial clones ( FIGS. 10 to 15 ) were isolated that represent six alleles from a gene family that may have at least 10 members. An analysis of RNA and enzyme activity from various stages of developing opium poppy seedlings and roots, stem, leaf and capsule of mature poppy plants indicated that transcript from these alleles is present throughout the plant at all developmental stages, with the highest total enzyme activity being in the capsule after petal fall. This would suggest that morphine biosynthesis occurs in all major plant organs starting within the first seven days after seed germination. Biosynthesis of morphine continues throughout the life cycle of this annual with the highest biosynthetic activity taking place in the capsule after petal fall, consistent with the amount of biosynthetic enzyme present. The amount of extractable RNA remained high in the capsule until three days after petal fall, after which time the quantity of extractable RNA decreased rapidly.
A biochemical analysis of four functionally expressed alleles, cor1.1-cor1.4, revealed no significant differences in the temperature or pH optima, K m values or substrate specificity of the isoforms. All isoforms were able to reduce morphinone to morphine.
Purification and Amino Acid Sequence Analysis of Opium Poppy Codeinone Reductase
Codeinone reductase was purified to apparent electrophoretic homogeneity from opium poppy cell suspension cultures and the amino acid sequence of seven endoproteinase Lys-C-generated peptides was determined ( FIG. 2 ). A comparison of these amino acid sequences with those available in the GenBank/EMBL sequence database allowed a relative positioning of peptides 7, 14 and 16 due to sequence homology with an NADPH-dependent reductase from members of the Fabaceae—alfalfa, glycyrrhiza and soybean (6′-deoxychalcone synthase) that synthesizes 4,2′,4′-trihydroxychalcone in co-action with chalcone synthase ( FIG. 3 ) (Welle et al., 1991). PCR primers were then designed based on the codeinone reductase peptide sequences. The sequences of the primers used in the first round of PCR were:
SEQ ID NO: 1
5′-GAA CTT TTT ATA ACT TCT AA-3′
(derived
G C C C G C
from Pep-
T
tide 14)
and
SEQ ID NO: 2
3′-GTG GTC TAA CGT CAI CGT TCI CCT TT-5′
(derived
A A G C
from Pep-
tide 7)
Resolution of an aliquot of the first PCR experiment by agarose gel electrophoresis revealed a mixture of DNA products, none of which was the expected band of approximately 480 bp. This was presumably due to the relatively low specificity of the degenerate primers coupled to a low abundance of codeinone reductase transcript. Another aliquot of the first PCR reaction mixture was, therefore, used as template for nested PCR with the following primers:
SEQ ID NO: 1 5′-GAA CTT TTT ATA ACT TCT AA-3′ (same as Pep- G C C C G C tide 14 primer T above) and SEQ ID NO: 3 3′-CAI CAC TTA GTT CAC CTT TAC-5′ (nested primer G C C derived from Peptide 16)
to yield an approximately 360 bp DNA fragment and the following primers to yield an approximately 180 bp DNA product:
SEQ ID NO: 4
5-′GTI GTI AAC CAA GTI GAA ATG AGI CCI AC-3′ (nested primer derived from
T G G TC Peptide 16) and
SEQ ID NO: 2
3′-GTG GTC TAA CGT CAI CGT TCI CCT TT-5′ (same as Peptide 7 primer above)
A A G C
The results from the nested PCR were bands of the expected size. The translation of the nucleotide sequences of these PCR products indicated that they encode codeinone reductase.
Isolation of cDNAs Encoding Codeinone Reductase
Screening of approximately 200,000 clones of a primary cDNA library prepared from opium poppy RNA isolated from capsule and cell suspension culture did not result in the identification of codeinone reductase clones. Likewise, difficulty was also confronted with detecting a band on RNA gel blots that corresponds to the size expected for codeinone reductase. In order to overcome the apparent problem of low steady state levels of codeinone reductase transcript, RACE-PCR was used to generate both the 5′- and 3′-portions of the cDNA (Frohman, 1993). A series of non-degenerate primers based on the nucleotide sequence information determined for the PCR product generated as described in the previous section were used for 5′- and 3′-RACE. The nucleotide sequence of the resultant 5′- and 3′- partial clones were thus determined in three major fragments and suggested the presence of isoforms. The full length cDNA clones were then generated by RT-PCR using the following primers and RNA isolated from opium poppy cell suspension culture as template:
SEQ ID NO: 5
5′-ATG GAG AGT AAT GGT GTA CCT-3′ (located at the 5′-terminus) and
SEQ ID NO: 6
3′-TCT ACC ATT CAC TCC TGA CAG-5′ (located in the 3′-flanking region)
followed by nested PCR with the following primer pair:
SEQ ID NO: 7
5′-ATG GCT AGC ATG GAG AGT AAT GGT GTA CCT ATG-3′ (located at the
Nhe 1 5′-terminus) and
SEQ ID NO: 8
3′-CTT CTC AAG ACC CTA CTC TTC CTA CCT AGG GAA-5′ (located at the
Bam HI 3′-terminus).
The PCR product was digested with the restriction endonucleases Nhe I/Bam HI, ligated into Nhe I/Bam HI digested pCAL-c and transformed into Escherichia coli BL21(DE)pLysS. Each cDNA was hence constructed in frame in front of DNA encoding a 25 amino acid long calmodulin-binding peptide to facilitate eventual heterologous protein purification. Single colonies were grown in 3 ml medium and were assayed for the ability to reduce codeinone. Of forty colonies tested, ten were found to contain functional enzyme. Nucleotide sequence determination of these ten cDNAs resulted in the identification of four alleles encoding codeinone reductase. The analogous PCR products had also been prepared with the cDNAs placed behind the calmodulin-binding peptide gene in pCAL-n-EK, but only the C-terminal fusion proteins bound the calmodulin affinity resin, indicating that the amino terminus of the fusion protein lies within the folded polypeptide.
By sequence comparison, codeinone reductase clearly belongs to the aldo/keto reductase family, a group of structurally and functionally related NADPH-dependent oxidoreductases. Members of this family possess three consensus sequences that are also positionally conserved: aldo/keto reductase consensus 1 (amino terminus)—G (F,Y)R(H,A,L)(L,I,V,M,F)D(S,T,A,G,C)(A,S) X X X X X E X X (L,I,V,M) G [cor1.1—G Y R H F D T A A A Y Q T E E C L G]; aldo/keto reductase consensus 2 (central)—(L,I,V,M,F,Y) X X X X X X X X X (K,R,E,Q) X (L,I,V,M) G (L,I,V,M) (S,C) N (F,Y) [cor1.1—M E E C Q T L G F T R A I G V C N F]; aldo/keto reductase consensus 3 (carboxy terminus)—(L,I,V,M) (P,A,I,V)(K,R)(S,T) X X X X R X X (G,S,T,A,E,Q,K) (N,S,L) X X (L,I,V,M,F,A)[cor1.1—V V K S F N E A R M K E N L K I]. This third consensus sequence is centred around a lysine residue, the modification of which has been shown to affect the catalytic efficiency of aldose and aldehyde reductases (Morjana et al., 1989).
The four functional full-length cDNAs (cor1.1, cor1.2, cor1.3 and cor1.4) encoding codeinone reductase share approximately 95–96% sequence identity ( FIG. 4 ). These sequences are comprised in microbial deposit Nos. DSM 12737, DSM 12738, DSM 12739 and DSM 12740 respectively, deposited at Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH (DSMZ) of Mascheroder Weg 1b, D-38124 Braunschweig, Germany on 16 Mar. 1999. In addition, a similar cDNA generated by PCR (cor2) was 70% identical to the codeinone reductase cDNAs, but was not functional. These opium poppy cDNAs were 53% identical to soybean NADPH-dependent reductase 6′-deoxychalcone synthase (Welle et al., 1991) ( FIG. 4 ), 33% identical to rat 3-hydroxysteroid dehydrogenase [EC 1.1.1.50], 38% identical to bovine prostaglandin F synthase [EC 1.1.1.188], 37% identical to apple D-sorbitol-6-phosphate dehydrogenase [EC1.1.1.200], 38% identical to bacterial ( Pseudomonas putida ) morphine 6-dehydrogenase [EC 1.1.1.218] and 35% identical to yeast ( Pichia stipitis ) xylose reductase (Amore at al., 1991).
Genomic DNA Analysis and Gene Expression Pattern
Genomic DNA was used as template for a PCR analysis of cor1.1–cor1.4. Each gene was found to contain one intron that was conserved in size (443 bp) and location (beginning after nucleotide +561) within the open reading frame, but not in nucleotide sequence. In comparison, cor2 contained two introns beginning after nucleotides +321 and +514. Genomic DNA gel blot analysis using cor1.1 as hybridization probe resulted in a complex hybridization pattern that suggests the presence of at least ten genes that could encode codeinone reductase in opium poppy ( FIG. 5 ). From the isolation and nucleotide sequence analysis of cDNA clones, it is certain that at least six of these ten genes are expressed in the plant and plant cell suspension culture. (Two additional partial cDNAs (cor1.5 and cor1.6; FIGS. 14 and 15 ) were generated by RT-PCR using plant RNA as template.) When the peptide sequences presented in FIG. 2 are compared with the translations of the cDNA sequences in FIG. 4 , it is clear that a mixture of isoforms was purified for amino acid sequence analysis. From the initial biochemical analysis of codeinone reductase, evidence for only two isoforms in the poppy plant and one isoform in poppy cell suspension culture was observed (Lenz and Zenk, 1995b).
RNA gel blot analysis indicated the presence of a very weakly hybridizing RNA of approximately 1.4 kb in poppy leaf, root and stem of a mature plant two days after petal fall ( FIG. 6 ). Since cor1 transcript was apparently present at very low levels, further analysis was undertaken by nested RT-PCR. Morphinan alkaloids begin to accumulate rapidly in poppy seedlings four to seven days after germination (Rush et al., 1985; Wieczorek et al., 1986). An analysis of codeinone reductase enzyme activity and transcript accumulation showed that enzyme activity is at 310 pkat/g dry tissue weight (dwt) already at day seven after germination (Table 1). This activity remains at that level throughout a three week growth period, then decreases to 148 pkat/g dwt by the eighth week. In comparison, opium poppy cell suspension culture also contains 330 pkat/g dwt enzyme activity. Transcript was detected by RT-PCR for cor1.1-cor1.4 at all developmental stages. Since two PCR amplifications were necessary in order to detect cor1 transcript, a comparative quantitation was not undertaken.
The distribution of codeinone reductase enzyme activity and transcript was also investigated in mature opium poppy plants two days after petal fall. On a dry tissue weight basis, most activity was present in the capsule (730 pkat/g dwt), then the lateral root (560 pkat/g dwt) followed by stem and leaf lamina (Table 2). Again, no differences could be found in the distribution pattern of the four isoforms by RT-PCR.
TABLE 1
Analysis of codeinone reductase enzyme activity and transcript in
developing opium poppy and in plant suspension culture.
Plant
Plant age
Specific activity
Total activity
Transcript
Material
(days)
(pkat/mg)
(pkat/dwt)
detection*
7
11
310
+
14
9
330
+
21
8
310
+
56
12
150
+
7
10
330
+
*Presence of transcript in each RNA population was determined by performing two nested PCR amplifications as described in the Examples.
TABLE 2 Analysis of codeinone reductase enzyme activity and transcript in developing opium poppy two days after petal fall. Plant Specific activity Total activity Transcript Part (pkat/mg) (pkat/dwt) detection a Capsule 25 730 + Stem b 30 250 + Leaf 10 120 + lamina Lateral 90 560 + root a Presence of transcript in each RNA population was determined by performing two nested PCR amplifications as described in the Examples. b Stem tissue beginning at the receptacle and extending 12 cm downwards was extracted. Plants were approximately 120 cm high.
Functional Characterization of the Codeinone Reductase Alleles
The four codeinone reductase isoform-calmodulin-binding peptide fusion proteins were purified from E. coli lysates in one step with a calmodulin affinity column. Beginning with 250 mg total protein in the bacterial extract, 10.5 mg codeinone reductase with a specific activity of 5.2 nkat/mg protein could be obtained in 73% yield. Aliquots from a typical purification analyzed by SDS-PAGE are shown in FIG. 7 . Codeinone reductase purified by this method is nearly homogeneous and demonstrated properties that compared favourably to those of the native enzyme (Lenz and Zenk, 1995b).
The temperature optimum, pH optimum and K m values for codeinone, codeine, NADPH and NADP were determined for each of the isoforms (K m values are indicated in Table 3). Significant differences in these values were not found. For all isoforms, the temperature optimum for reduction (physiologically forward reaction) was 28° C., for oxidation (physiologically reverse reaction) was 30° C., the pH optimum for reduction was 6.8 and for oxidation was 9.0. The isoforms were also tested for their ability to transform morphinan alkaloids structurally related to codeinone and codeine. The reductive reaction with NADPH as cofactor functions with morphinone, hydrocodone and hydromorphone as substrate. The oxidative reaction with NADP as cofactor functions with morphine and dihydrocodeine as substrate. The K m values for, and structures of, these additional substrates with COR1.3 are shown in FIG. 8 . In all cases, the physiologically forward reaction yielded lower K m values than the physiologically reverse reaction, with codeinone having the lowest K m value at 48 μM. No differences in temperature or pH optimum were observed whether codeinone or morphinone were used as substrate in the assay. NADH could not substitute for NADPH with any of the isoforms. Tritium was enzymatically transferred to codeinone from [4R- 3 H]NADPH, but not from [4S- 3 H]NADPH, indicating that codeinone reductase stereospecifically abstracts the pro-R hydrogen from the cofactor.
TABLE 3
Comparison of properties of codeinone reductase isoforms
COR1.1
COR1.2
COR1.3
COR1.4
Amino acid identity
100
95
96
96
(%)
K m codeinone (μM)
58
62
48
50
K m NADPH (μM)
180
220
205
197
K m codeine (μM)
220
200
187
140
K m NADP (μM)
53
58
45
55
Calculated M r
35,808
35,704
35,797
35,705
Calculated pl
6.25
5.71
6.32
6.33
The reduction of codeinone to codeine is the last of three NADPH-dependent reductions that occur along the biosynthetic pathway leading from (S)-reticuline to morphine in opium poppy. The two other potential substrates for reduction, the 1,2-dehydroreticulinium ion and salutaridine ( FIG. 1 ), or for the physiologically reverse reaction, salutaridinol and (R)-reticuline, were tested as substrates; with the codeinone reductase isoforms. None of these alkaloids served as substrate indicating that codeinone reductase can catalyze only one reductive step in morphine biosynthesis. In addition, the following analogs were also inactive: (S) and (R)-norreticuline, (S)-reticuline and norcodeine.
Since codeinone reductase showed sequence similarity to several members of the aldo/keto reductase family, a series of substrates were tested to reflect members from carbohydrate and steroid metabolism. D-Sorbitol-6-phosphate, D-xylose, prostaglandin D1,5-androstene-3β,17β-diol, 5α-androstan-17β-ol-3-one, 5α-cholestane-3β-ol, β-estradiol, cyclohexanone and 2-cyclohexene-1-one were not transformed by codeinone reductase. The highest amino acid sequence identity (53%) was, however, to the reductase subunit of the 6′-deoxychalcone synthase complex from soybean (Welle et al., 1991). In order to test for a functional evolutionary relationship between isoflavonoid and alkaloid anabolism, codeinone reductase was analyzed for the ability to substitute for the reductase in the formation of 6-deoxychalcone in co-action with either native chalcone synthase or native stilbene synthase from Pinus sylvestris . In the presence of 4-coumaryl-CoA, malonyl-CoA, NADPH, chalcone synthase and codeinone reductase or cinnamoyl-CoA, malonyl-CoA, NADPH, stilbene synthase and codeinone reductase, formation of product was not observed. Likewise, the reductase of the 6′-deoxychalcone synthase complex could neither reduce codeinone in the presence of NADPH nor oxidize codeine in the presence of NADP.
EXAMPLE 1
Purification of Native Enzyme and Amino Acid Sequence Analysis
Cell suspension cultures of the opium poppy Papaver somniferum were routinely grown in either 1-liter conical flasks containing 400 ml of Linsmaier-Skoog medium (Linsmaier and Skoog, 1965) over 7 days at 23° C. on a gyratory shaker (100 rpm) in diffuse light (750 lux). Differentiated opium poppy plants were grown outdoors in Upper Bavaria. Seedlings were grown on substrate from 7 to 56 days in a greenhouse at 20° C., 65% relative humidity and 12 h cycles of light and dark.
A mixture of codeinone reductase isoforms was purified from opium poppy cell suspension cultures exactly according to Lenz and Zenk (1995b). The purified enzyme preparation was subjected to SDS/PAGE to remove traces of impurities and the coomassie brilliant blue R-250-visualized band representing codeinone reductase was digested in situ with endoproteinase Lys-C as reported in (Eckerskorn and Lottspeich, 1989, Dittrich and Kutchan, 1991). The peptide mixture thereby obtained was resolved by reversed phase HPLC [column, Merck Lichrospher RP18; 5 μm (4×125 mm); solvent system, (A) 0.1% trifluoroacetic acid, (B) 0.1% trifluoroacatic: acid/60% acetonitrile; gradient of 1% per min; flow rate of 1 ml/min] with detection at 206 nm. Microsequencing of seven of the peptides thus purified was accomplished with an Applied Biosystems model 470 gas-phase sequencer.
EXAMPLE 2
Generation of Partial and Full-Length cDNAs from Opium Poppy
Partial cDNAs encoding codeinone reductases from opium poppy were produced by PCR using cDNA produced by reverse transcription of total RNA isolated from 3 to 5-day-old suspension cultured cells. DNA amplification using either Taq or Pfu polymerase was performed under the following conditions: 4 min at 94° C., 35 cycles of 94° C., 30 sec: 45° C., 30 sec; 72° C., 1 min. At the end of 35 cycles, the reaction mixtures were incubated for an additional 5 min at 72° C. prior to cooling to 4° C. Reamplification of DNA using nested primers was performed as above, but the primer annealing temperature was raised from 45 to 55° C. The amplified DNA was then resolved by agarose gel electrophoresis, the bands of approximately the correct size were isolated and subcloned into pGEM-T (Promega) prior to nucleotide sequence determination. The specific sequences of the oligodeoxynucleotide primers used are indicated above.
Total RNA was isolated and RNA gels were run and blotted as previously described (Pauli and Kutchan, 1998). Genomic DNA was isolated and DNA gels were run and blotted according to Bracher and Kutchan (1992). cDNA clones were labelled by random-primed labelling with [α- 32 P]dCTP and oligodeoxynucleotides were end-labelled with [γ- 32 P]ATP. Hybridized RNA on Northern blots and DNA on Southern blots were visualised with a Raytest BAS-1500 phosphorimager. The entire nucleotide sequence on both DNA strands of full-length cDNA clones in either pGEM-T or pCAL-c was determined by dideoxy cycle sequencing using internal DNA sequences for the design of deoxyoligonucleotides as sequencing primers.
The sequence information requisite to the generation of full-length cDNAs was derived from the nucleotide sequences of the partial cDNAs generated as described above. The complete nucleotide sequence of one reading frame was determined using codeinone reductase specific oligodeoxynucleotide primers in 5′- and 3′-RACE-PCR experiments with a Marathon™ cDNA amplification kit (Clontech). RACE-PCR was performed using the PCR cycles described above. The amplified DNA was then resolved by agarose gel electrophoresis and the band of the approximate expected size was isolated, subcloned into pGEM-T and sequenced.
Nested primer pairs were then used to generate full-length clones for heterologous expression by RT-PCR using opium poppy cell suspension culture RNA as template. The final primers used in clone amplification contained the restriction endonuclease recognition sites Nhe I and Bam HI that were appropriate for subcloning directly into the pCAL-c (Stratagene) expression vector. The specific sequences of these primers are indicated above. RT-PCR was carried out using the PCR cycles given above. The amplified DNA was then resolved by agarose gel electrophoresis and the band of the correct size (972 bp) was excised and isolated for further subcloning into the expression vector.
EXAMPLE 3
Heterologous Expression and Enzyme Purification
Full-length cDNAs generated by RT-PCR were ligated into p-CAL-c and transformed into the E. coli strain BL21(DE3)pLysS. For enzyme assays, single colonies were picked and grown in 3 ml Luria-Bertani medium containing 100 μg/ml ampicillin at 37° C. to an OD 590 of 0.8. For protein purification, single colonies were picked and grown in 1 l Luria-Bertani medium containing 100 μg/ml ampicillin at 37° C. to an OD 590 of 1.8. Cells were collected by centrifugation 5 min at 4,000×g and 4° C. The bacterial pellet was resuspended in either 0.1 M potassium phosphate buffer pH 6.8 for the reduction of codeinone or 0.1 M glycine buffer pH 9 for the oxidation of codeine. The bacterial pellet from a 3 ml culture was resuspended in 0.5 ml buffer and that from a one liter culture in 100 ml buffer. The cells were ruptured by sonication. Cellular debris was removed by centrifugation 5 min at 4,000×g and 4° C. and the supernatant used directly for either affinity chromatography purification using the Affinity™ Protein Expression and Purification System according to the manufacturer's instructions (Stratagene) or for enzyme activity measurements according to Lenz and Zenk (1995b).
EXAMPLE 4
Enzyme Assay and Product Identification
The oxidative and reductive reactions catalyzed by codeinone reductase were assayed according to Lenz and Zenk (1995b). The oxidation of codeine to codeinone by heterologously expressed enzyme in a crude bacterial extract was used for large scale production of enzymic product for structure elucidation by 1 H NMR, 13 C NMR and mass spectrometry. The enzyme assays were extracted twice with two volumes of CHCl 3 , the combined organic phase was reduced in vacuo and resolved by semipreparative HPLC using the following gradient: [column, Knauer LiChrosopher 100 RP18 endcapped; 5 μm (16×250 mm); solvent system, (A) 97.99% (v/v) H 2 O 2% CH 3 CN, 0.01% (v/v) H 3 PO 4 , (B) 1.99% (v/v) H 2 O, 98% CH 3 CN, 0.01% H 3 PO 4 ; gradient: 0–9 min 0–8% B, 9–24 min 8% B, 24–45 min 8–25% B, 45–75 min 25% B, 75–75.3 min 25–0% B, 75.3–90 min 0% B; flow 4.5 ml/min] with detection at 204 nm using authentic codeine (retention time, 38 min) and codeinone (retention time, 49 min) as reference materials. In this manner, 10 mg codeinone was enzymically produced and purified.
Codeinone— 1 H (360 MHz, CDCl 3 ) 1.87 (1H, dd J 15a/15e 12.2, J 15c/15a 3.1, H-1 Se), 2.08 (1H, ddd, J 15a/16a 4.5, J 15a/15e 12.2, H-15 a ) 2.29 (1H, ddd, J 15a/16a 12.3, J 15e/16a 3.1, J 16a/16c 3.1, J 16a/16e 11.8, H-16 a ), 2.35 (1H, dd, J 10a/10e 18.5, J 9/10a 5.9, H-10 a ), 2.47 (3H, s, CH 3 N—), 2.63 (1H, dd, J 16a/16c 11.8 J 15a/16c 4.5, H-16 e ), 3.12 (1H, d, J 10a/10c 18.5, H-10 c ), 3.21 (1H, m, H-14), 3.43 (1H, m, H-9), 3.85 (3H, s, CH 3 O—), 4.71 (1H, s, H-5), 6.09 (1H, dd, J 7/8 10.1, J 7/14 2.8, H-7), 6.62 (1H, d, J 1/2 8.3, H-1), 6.66 (1H, dd, J 7/8 10.1, J 8/14 1.5, H-8), 6.68 (1H, d, J 1/2 8.3, H-2); 13 C (90.6 MHz, CDCl 3 ) 20.5 (C-10), 33.8 (C-15), 41.3 (C-14), 42.8 (NMe), 43.0 (C-13), 46.8 (C-16), 56.8 (OMe), 59.1 (C-9), 88.0 (C-5), 114.8 (C-2), 119.9 (C-1), 125.7 (C-11), 128.9 (C-12), 132.6 (C-7), 142.6 (C-3), 144.9 (C-4) 148.7 (C-8), 194.4 (C-6); EI-MS (70 eV), m/z 297 (M + , 100%, 282 (8), 268 (9), 254 (8), 238 (9), 229 (23), 214 (17), 188 (15) 165 (11), 152 (13), 139 (16), 128 (22), 115 (41).
EXAMPLE 5
Transformation of Plants with Nucleotide Sequences from Genes Encoding Codeinone Reductase Proteins
Plant Materials
Two plant lines were used in transformation experiments. These were Nicotiana tabacum line Wisconsin38, and Papaver somniferum line C048. Preparation of plant materials and tissue culture and transformation conditions were as described in An et. al (1986), Hooykaas and Schilperoort (1992) and PCT Application PCT/AU99/00004, all of which are incorporated herein by reference.
Bacterial Strains and Vectors
The disarmed Agrobacterium tumefaciens strain LBA4404 was used in transformation experiments. DNA constructs capable of expressing the codeinone reductase genes were prepared in a binary vector containing a 35 S-nptII selectable marker, and transformed into the N. tabacum and P. somniferum lines.
Successful transformation of these plant lines was achieved as judged by
(a) regeneration of N. tabacum plants on medium containing 100 mg/l kanamycin indicating expression of the nptII selectable marker, which was verified by NPTII enzyme assays. Coexpression of the codeinone reductase gene was determined by RT-PCR (reverse transcriptase polymerase chain reaction) assay.
(b) successful selection of transformed cell cultures of P. somniferum using the same nptII selectable marker indicative of expression from the vector, followed by the generation of typeI and typeII embroyogenic callus prior to the production of transformed plants.
Thus, the identification and cloning of genes for codeinone reductase from P. somniferum now provides a means by which alteration of the enzymatic step(s) involving this can be achieved. The overexpression of these sequences can be achieved using vectors which express one or more of the codeinone reductase alleles, while downregulation of general codeinone reductase activity or the activity of specific alleles can be achieved using vectors expressing antisense, ribozymes, plus-sense cosuppression or RNAi sequences from regions conserved between the codeinone reductase alleles or other sequences which are unique to each allele. These genes encoding the sense, antisense, ribozyme, RNAi or other such sequences can be delivered as transgenes stably integrated into the poppy genome or transiently in the form of a viral vector.
Although the invention has been described with reference to specific embodiments, modifications that are within the knowledge of those skilled in the art are also contemplated as being within the scope of the present invention.
REFERENCES
Amore, R., Koetter, P., Kuester, C., Cirlacy, M., and Hollenberg, C. P. (1991). Cloning and expression in Saccharomyces cerevisiae of the NAD(P)H-dependent xylose reductase-encoding gene (XYL1) from the xylose-assimilating yeast Pichia stipitis . Gene 109, 89–97.
An, G., Watson, B. D., Chiang, C. C. (1986). Transformation of tobacco, tomato, potato and Arabidopsis thaliana using a binary Ti vector system. Plant Physiology 81:301–305.
Bracher, D., and Kutchan, T. M. (1992). Strictosidine synthase from Rauvolfia serpentina : Analysis of a gene involved in indole alkaloid biosynthesis. Arch. Biochem. Biophys. 294, 717–723.
Brochmann-Hanssen, E. (1984). A second pathway for the terminal steps in the biosynthesis of morphine. Planta Med. 50, 343345.
De-Eknamkul, W., and Zenk, M. H. (1992). Purification and properties of 1,2-dehydroreticuline reductase from Papaver somniferum seedlings. Phytochemistry 31, 813–821.
Dittrich, H., and Kutchan, T. M. (1991). Molecular cloning, expression and induction of berberine bridge enzyme, an enzyme essential to the formation of benzophenanthridine alkaloids in the response of plants to pathogenic attack. Proc. Natl. Acad. Sci. USA 88, 9969–9973.
Eckerskorn, C., and Lottspelch, F. (1989). Internal amino acid sequence analysis of proteins separated by gel electrophoresis after tryptic digestion in polyacrylamide matrix. Chromatographia 28, 92–94.
Facchini, P. J., and De Luca, V. (1994). Differential and tissue-specific expression of a gene family for tyrosine/dopa decarboxylase in opium poppy. J. Biol. Chem. 269, 26684–26690.
French, C. E., Hailes, A. M., Rathbone, D. A., Long, M. T., Willey, D. L., and Bruce, N. C. (1995). Biological production of semisynthetic opiates using genetically engineered bacteria. Biotechnology 13. 674–676.
Frohman, M. A. (1993). Rapid amplification of complementary DNA ends for generation of full-length complementary DNAs: Thermal RACE. Methods Enzymol. 218, 340–356.
Gerardy, R. and, Zenk, M. H. (1993). Purification and characterization of salutaridine: NADPH 7-oxidoreductase from Papaver somniferum . Phytochemistry 34, 125–132.
Goliwitzer, I., Lenz, R., Hampp, N., and Zenk, M. H. (1993). The transformation of neopinone to codeinone in morphine biosynthesis proceeds non-enzymatically. Tetrahedron Lett. 34, 5703–5706.
Hooykaas, P. J. and Schilperoort, R. A. (1992). Agrobacterium and plant engineering. Plant Molec. Biol. 19:15–38.
Kutchan, T. M., Ayabe, S., and Coscia, C. J. (1985). Cytodifferentiation and Papaver alkaloid accumulation. In The Chemistry and Biology of Isoquinoline Alkaloids , (Phillipson, J. D., Roberts, M. F., Zenk, M. H., eds) Berlin: Springer-Verlag, pp. 281–294.
Kutchan, T. M., Rush, M. D., and Coscia, C A. (1986). Subcellular localization of alkaloids and dopamine in different vacuolar compartments of Papaver bracteatum . Plant Physiol. 81, 161–166.
Kutchan, T. M. (1998). Molecular genetics of plant alkaloid biosynthesis. In The Alkaloids Vol. 50, (Cordell, G., ed) San Diego: Academic Press, pp. 257–316.
Lenz, R., and Zenk, M. H. (1995a). Stereoselective reduction of codeinone, the penultimate enzymic step during morphine biosynthesis in Papaver somniferum . Tetrahedron Lett. 36, 2449–2452.
Lenz, R., and Zenk, M. H. (1995b). Purification and properties of codeinone reductase (NADPH) from Papaver somniferum cell cultures and differentiated plants. Eur. J. Biochem. 233, 132–139.
Linsmaier, E. M., and Skoog, F. (1965). Organic growth factor requirements of tobacco tissue cultures. Physiol. Plant. 18, 100–127.
Liras, P., Kasparian, S. S., and Umbreit, W. W. (1975). Enzymatic transformation of morphine by hydroxysteroid dehydrogenase from Pseudomonas testosteroni . Applied Microbiol. 30, 650–656.
Morjana, N. A., Lyons, C., and Flynn, T. G. (1989). Aldose reductase from human psoas muscle. Affinity labelling of an active site lysine by pyridoxal 5′-phosphate and pyridoxal 5′-diphospho-5′-adenosine. J. Biol. Chem. 264, 2912–2919.
Nessler, C. L., and Mahiberg, P. G. (1977). Ontogeny and cytochemistry of alkaloidal vessicles in laticifers of Papaver somniferum L. (Papaveraceae). Amer. J. Bot. 64, 541–551.
Nessler, C. L., and Mahiberg, P. G. (1978). Laticifer ultrastructure and differentiation in seedlings of Papaver bracleatum L., Population Arya 11 (Papaveraceae). Amer. J. Bot. 65, 978–983.
Nielsen, B., Röe, 1, and Brochmann-Hanssen, E. (1983). Oripavine—A new opium alkaloid. Plant Med. 48, 205–206.
Pauli, H. H., and Kutchan, T. M. (1998). Molecular cloning and functional heterologous expression of two alleles encoding (S)-N-methylcoclamine 3′-hydroxylase (CYP80B1), a new methyl jasmonate-inducible cytochrome P450 dependent monooxygenase of benzylisoquinoline alkaloid biosynthesis. Plant J. 13, 793–801.
Roberts, M. F., McCarthy, D., Kutchan, T. M., and Coscia, C. J. (1983). Localization of enzymes and alkaloidal metabolites in Papaver latex. Arch. Biochem. Biophys. 222,599–609.
Rosco, A., Pauli, H. H., Priesner, W., and Kutchan, T. M. (1997). Cloning and heterologous expression of cytochrome P450 reductases from the Papaveraceae. Arch. Biochem. Biophys. 348, 369–377.
Rush, M. D., Kutchan, T. M., and Coscia, C. J. (1985). Correlation of the appearance of morphinan alkaloids and laticifer cells in germinating Papaver bracteatum seedlings. Plant Cell Rep. 4, 237–240.
Sertürner, F. W. A. F. (1806). Darstellung der reinen Mohnsäure (Oplumsäure) nebst einer chemischen Untersuchung des Opiums mit vorzüglicher Hinsicht auf einen darin neu entdeckten Stoff und die dahin gehörigen Bemerckungen. J. Pharm. Ärzte Apotheker Chem. 14/1, 47–93.
Welle, R., Schroder, G., Schiltz, E, Grisebach, H., and Schroder, J. (1991). Induced plant responses to pathogen attack—Analysis and heterologous expression of the key enzyme in the biosynthesis of phytoalexins in soybean ( Glycine max L. Merr. cv. Harosoy 63). Eur. J. Biochem. 196. 423–430.
Wieczorek, U., Nagakura, N., Sund, C., Jendrzejewski, S., and Zenk, M. H. (1986). Radioimmunoassay determination of six opium alkaloids and its application to plant screening. Phytochemistry 25, 2639–2646.
Ye, K., Ke, Y., Keshava, N., Shanks, J., Kapp, J. A., Tekmal, R. R., Petros, J., and Joshi. H. C. (1998). Opium alkaloid noscapine is an antiturnor agent that arrests metaphase and induces apoptosis in dividing cells. Proc. Natl. Acad. Sci. USA 95, 16011606.
Yin, S.-J., Vagelopoulos, N., Lundquist, G., and Jornvall, H. (1991). Pseudomonas 3′-hydroxysteroid dehydrogenase—Primary structure and relationships to other steroid dehydrogenases. Eur. J. Biochem. 197, 7359–365.
Zenk, M. H. (1994). Über das Opium, das den Schrnerz besiegt und die Sucht weckt. Bayerische Akademie der Wissenschaften, Jahrbuch 1993, München: C. H. Beck'sche Verlagsbuchhandlung, pp. 98–126. | The present invention concerns codeinone reductase from alkaloid poppy plants, the polynucleotides encoding the enzyme, transgenic plants transformed or transfected with polynucleotide(s) encoding codeinone reductase and to the production of alkaloids from transformed or transfected poppy plants. | 2 |
CROSS-REFERENCE DATA
This is a Continuation-in-Part of U.S. patent application No. 08/867,024 filed on Jun. 2, 1997 now abandoned, by the present applicant.
FIELD OF THE INVENTION
The present invention relates to aid apparatuses for hearing impaired persons, and more particularly to a video-assisted apparatus for hearing impaired persons.
BACKGROUND OF THE INVENTION
It is common for hearing impaired persons to use portable amplifier devices that can be hooked on and supported by the ear, and more particularly behind the auricle, with a semi-flexible pipe extending into the acoustic meatus. These devices amplify the sounds so as to allow the hearing impaired person to more clearly hear surrounding sounds. Howver, when the hearing disability is acute, or when the person is completely deaf, these amplifier devices may not be sufficient or may be entirely useless.
People with this acute hearing disability or complete deafness communicate via a sign language and via reading the movement of the lips of the person transmitting information. Even when the hearing disability is not extremely important, reading the lips of the interlocutor is computer practice, and can be used concurrently with the hearing aid device, to help understand the sometimes less understandable pronunciation of a speaker person. When the speaker does not have free access to use its hands during conversation, especially teachers having to manipulate board chalks, notes for their courses or other devices, the reading of the lips takes a particular importance, since sign language cannot be relied upon.
However, for the lip reading to be readily accomplished, the teacher must always face its class students. Moreover, the number of students is then limited, because of the maximum distance from the teacher which can be tolerated, for lip reading by a student located far away from the teacher will be significantly hampered, if not completely impossible. Also, a teacher facing a particular portion of the class students would do so to the detriment of others. Finally, the teacher may not readily use the blackboard usually located at the front end of the class, behind the teacher, while simultaneously talking, for the teacher would then be turning his back to the class students, who could not see his lips and therefore could not accomplish the lip reading.
In an era where most types of professions are accessible to the hearing impaired or deaf persons, it is possible also that the teacher be called upon to manipulate machinery, work on wood components, or work in many other fields requiring hand held equipment, in which sign language is difficult, if not impossible, during the equipment operation, and in which lip reading can be difficult, depending on the equipment used.
U.S. Pat. No. 5,886,735 issued in 1999 to E. T. Bullister shows a headset including a head-engaging frame supporting a camera which, directly or through a reflecting mirror, will film the facial area of the person wearing the headset. The headset can be provided with a microphone. The person wearing the headset is thus able to transmit both his image and his speech through computerised means, for allowing videoconferencing. The subject matter disclosed in the Bullister patent is especially oriented towards the question of the correction of the distortion of the image obtained by the camera, since the camera is positioned in a closely adjacent fashion relative to the face of the person wearing the headset.
One problem with the system disclosed in the Bullister patent is that the image transmission does not occur in real time. According to the person skilled in the art of the present invention, real time is defined as a maximum delay of 33 msec (milliseconds) between the moment when the image is perceived and the moment when the sound is perceived (c.f. “The Effect of Imperfect Cues on the Reception of Cued Speech”, written by Maroula Sarah Bratakos of the Massachusetts Institute of Technology, September 1995). In the Bullister patent, software image correction occurs, while is time-consuming, i.e. at least about 500 msec for a full image. Furthermore, signal compression through a MPEG compressor takes place, which delays the image transfer of approximately 33 msec, as does the decompression through a MPEG decompressor, the latter not being shown in the Bullister patent, but being necessary to decompress the image compressed by the MPEG compressor. Thus, important delays amounting to up to 2000% and more of a real time transmission, occur with the device shown in the Bullister patent.
This relatively important time delay in the transmission of the images during video-conferencing, is not a problem with the system of the Bullister patent, since there is no need for precise real time transmission of the image in video-conferencing technology. Indeed, since the sound transferred through the computerised means can be synchronised with the image, the videoconferencing participants will not notice any time delay between the sound and the image being transferred. A 100 to 600 msec delay can occur without hampering significantly the video-conference. However, this important time delay can and does become an important problem in the field of the present invention.
Another problem associated with the system of the Bullister patent, is that it uses phone lines to transmit its information, using a modem. Again, this is not a problem in the field of video-conferencing, but is a problem in the field of the present invention. Indeed, the cumbersome computer, with wires and casings, it not adapted for high mobility purposes in which freedom of movement is required.
Yet another problem associated with the device shown in the Bullister patent, is that it includes an image correction device. The Bullister patent shows this device as either a distortion correction software, which is time consuming as detailed hereinabove; or a mirror or a lense which will both diminish the quantity of light received by the camera, and thus the image will be obscured.
International patent application filed under number PCT/JP85/00398 and published under number WO 86/01060 on Feb. 13, 1986—inventor Hiroshi ONO—discloses a data transmitting device using a telephone. FIG. 6 of the Ono patent application shows an embodiment of this invention in which a teacher uses the system according to the Ono application, for the benefit of hearing-impaired students in a class. Indeed, the teacher is equipped with a headset carrying a camera filming the teacher's lips, and transmitting this information to a screen provided on the hearing impaired student's desk to allow the student to accomplish lip-reading on the screen when he cannot directly view the teacher's lips.
An important problem with the system according to the Ono application, is that a telephone data transmission occurs. Indeed, the heart of the Ono application relies on the data phone-type transmission, including wires linking the camera headset to the end visualising screens. This is very undesirable, for three reasons:
1) the telephone system shown in the Ono application is heavy and cumbersome; 2) the wires linking all the elements are also very cumbersome, especially since they limit the movements of the teacher, who may become entangled in his wires; and 3) use of the phone lines restricts the quantity of information that can be sent to the screens; for example, conventional phone lines are limited to frequencies which are not higher than 3500 Hz, with the consequence that high-frequency syllables or letters, for example the letters “s”, “f” and “th”, become very difficult to hear and differentiate from one another. This is to be compared to the 20 Hz minimum to 20,000 Hz maximum range of frequency of sounds for which the normal person can be sensitive with his ears.
OBJECTS OF THE INVENTION
It is the gist of the invention to provide an apparatus for allowing hearing impaired persons or deaf persons to understand a speaker by reading his lips, while allowing this speaker to have freedom of movement, especially of his head and hands.
It is an important object of this invention that this apparatus be light and uncumbersome for the person using it.
It is yet another object of this invention that many hearing impaired or deaf persons may simultaneously profit from this apparatus used by the speaker, notwithstanding their position relative to the speaker.
It is another object of the invention to provide a device of the character described, which is to be used across short distances for allowing a low-power transmission to occur.
It is an object of the present invention that the speech and images be transmitted across two different transmission channels.
SUMMARY OF THE INVENTION
The present invention relates to a real-time video-assisted apparatus for use by a speaker and hearing impaired persons, for reproducing in real-time an image of the speaker's mouth, comprising:
a headset frame to be removably installed on the head of the speaker; a real-time image transmission and display circuit including:
a) a miniature camera rigidly carried by said headset from ahead of the speaker's mouth and destined to target at least the speaker's mouth for catching continuous video images therefrom; b) a low-power video transmitter operatively linked to said camera, for coding the video images caught by said camera and for real-time transmission thereof as a low-power wireless video signal, said video transmitter including a power device for powering said camera and said video transmitter; c) at least one video receiver, located substantially closely to said video transmitter, for receiving said low-power wireless video signal in real-time from said video transmitter and decoding it into video images; and d) at least one visualising device operatively linked to said at least one video receiver, for visualising the images decoded by said video receiver in real-time relative to the sound emitted by the speaker;
wherein said apparatus includes a real-time transmission of the images of the speaker's mouth to said at least one visualising device, whereby at least the lip movements and preferably all facial expressions of the speaker are followed in real-time simultaneously by any number of hearing impaired persons looking at the visualising device notwithstanding the head orientation or position of the speaker relative to the hearing impaired persons.
Preferably, said video transmitter emits said video signal at a maximum field strength of 50 millivolts per meter measured at a distance of three meters from said video transmitter.
Preferably, said video assisted apparatus further comprises:
a microphone carried by said headset frame and linked to an audio transmitter, for catching the sound waves emitted by the speaker's voice in a continuous fashion; a low-power audio transmitter operatively linked to said microphone, for coding the sounds caught by said microphone and for real-time transmission thereof as a low-power wireless audio signal, said audio transmitter including a power device for powering said microphone and said audio transmitter; at least one audio receiver, located substantially closely to said audio transmitter, for receiving said low-power wireless audio signal in real time from said audio transmitter and decoding it into sounds; and at least one amplifying device operatively linked to said at least one audio receiver, for emitting the sounds decoded by said audio receiver in real-time relative to the sound emitted directly by the speaker;
wherein said apparatus includes a real-time transmission of the sounds of the speaker's mouth to said at least one amplifying device, whereby the speech of the speaker can be simultaneously heard directly from the speaker and through said video-assisted apparatus.
Preferably, said audio transmitter emits said audio signal at a maximum field strength of 80 millivolts per meter measured at a distance of 3 meters from said audio transmitter.
Preferably, said video transmitter and said audio transmitter are distinct, and wherein said audio receiver and said video receiver are also distinct, whereby said wireless video signal and said wireless audio signal are transmitted as two distinct signals on respective wave bands.
Preferably, said video signal is transmitted in the frequency range of 902-928 MHz, while said audio signal is transmitted in the frequency range of 72-76 MHz.
Preferably, said video transmitter and said audio transmitter are a single transmitter element, whereby said audio signal and said video signal are transmitted as a single, combined signal.
Preferably, said amplifying device is a hearing aid device.
Preferably, said microphone, said audio transmitter and said audio receiver are sensitive to a frequency range substantially within the average human sound sensitivity of 20 Hz to 20,000 Hz.
DESCRIPTION OF THE DRAWINGS
In the annexed drawings:
FIG. 1 is a perspective view showing a school teacher wearing a headset including to the video-assisted apparatus of the invention, with two students located behind her at their respective desks, on which are installed video monitor screens of the video-assisted apparatus; and
FIG. 2 is an enlarged perspective view of the headset portion of the video-assisted apparatus, with the headset being partly fragmented and with the camera support arm being partly broken, and suggesting with several arrows the possible headset adjustments for orienting and positioning the camera relative to the teacher's mouth and to compensate for various head sizes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a preferred embodiment of a video-assisted apparatus 10 for use by a speaker S and a number of hearing impaired persons H. Apparatus 10 comprises a headset frame 12 equipped with a small camera 14 , a transmitter 16 , a number of remotely located receivers 18 and an equal number of visualising means in the form of television or computer screens or LCD or LED screens 20 . Apparatus 10 also comprises a microphone 47 .
As shown in FIG. 2 , headset frame 12 resembles conventional receptionist-style phone headset frames and comprises a flat arcuate rigid headpiece 22 defining a first and a second end 22 a and 22 b, headpiece 22 forming substantially a 180° (half-turn) arc. Rigid headpiece 22 comprises a slight flexibility, to allow its two ends 22 a, 22 b to be manually forcibly parted, to be inserted onto a persons's head and thereafter snugly engage same, as will be explained hereinafter.
On headpiece first end 22 a is fixed a triangular, rigid first abutment member 24 , on the interior face of which a temple padding cushion 26 is provided for the comfort of the user's head.
Headpiece 22 frictionally engages and extends through a cylindrical socket member 28 and its second end 22 b is provided with a circumferential stopper 30 that prevents socket 28 from accidentally releasing headpiece 22 . By forcibly sliding headpiece 22 through socket member 28 against the friction force therein, an adjustment of the dimension of headset 12 is acquired to fit heads of different sizes, as known in the art. Socket member 28 is fixedly attached to a rigid, inverted U-shaped second abutment member 32 having a pair of downwardly extending legs 32 a, with only one of these legs being shown in FIG. 2 for clarity of the drawing. Each leg 32 a is provided with an interior padding cushion 33 , for the comfort of the user's head.
The outer flat surface of cylindrical socket 28 is equipped with a small axially projecting stud 34 which frictionally snaps into a complementary hole 36 made through the inner flat surface of a hollow cylindrical dial 38 which rests against and axially and diametrally registers with socket 28 . Dial 38 has a pair of diametrally aligned notches 38 a, 38 b axially extending in its cylindrical peripheral surface, opposite socket 28 , through which a hollow, elongated cylindrical camera supporting arm 40 is installed. An inner grooved compression cap 42 engages and holds arm 40 at the position in which it is installed, due to a threaded outer cap 44 which threadingly engages dial 38 so as to apply axial pressure on compression cap 42 which frictionally traps arm 40 in notches 38 a, 38 b to prevent linear displacement thereof. Therefore, the position of arm 40 can be selectively adjusted along dial 38 by removing caps 42 , 44 and sliding arm 40 inside notches 38 a, 38 b, as suggested by arrow A 1 in FIG. 2 ; the position of arm 40 can then be frictionally fixed relative to dial 38 by installing caps 42 , 44 and threadingly tightening outer cap 44 on dial 38 . Moreover, the angular position of arm 40 can be selectively adjusted by forcibly turning dial 38 against the friction force of stud 34 against hole 36 , as suggested by arrow A 2 in FIG. 2 , and then releasing arm 40 at the desired angular position.
Supporting arm 40 defines a first and a second opposite ends 40 a, 40 b, with first end 40 a being located proximate dial 38 and second end 40 b supporting camera 14 . FIG. 1 further shows that arm 40 is elbowed at two intermediate locations, 40 c and 40 d, for ergonomically conforming to the general shape of the face of the speaker S, as is known in the state of the art headsets.
Camera 14 is of the conventional miniature type. Preferably, it is approximately cubic with a side dimension of approximately 1.25 centimeters. This miniature camera is small, uncumbersome and of light weight, and therefore will not hamper or distract the speaker S when she is talking. As seen in FIG. 2 , camera 14 is installed on a joint 46 and has a lens 48 destined to target the mouth of the speaker, as will be explained hereinafter. Joint 46 is shown to be cylindrical and thus allow up and down orientation adjustment of lens 48 by rotation of camera 14 according to arrow A 3 in FIG. 2 . In an alternate embodiment, not shown, joint 46 could also be a universal ball-joint, allowing for rotation along all three perpendicular axes of camera 14 , so that lens 48 may be selectively oriented in a great variety of directions.
FIGS. 1 and 2 suggest that supporting arm 40 is hollow, and houses a wire 50 connected to camera 14 , running in arm 40 and protruding beyond the arm (tip) first end 40 a and down behind the back of the speaker S. Wire 50 is plugged to transmitter 16 at its other (bottom) end, and thus links camera 14 thereto. Transmitter 16 includes an intrinsic and autonomous power means, preferably in the form of a portable 12 Volt battery, for powering transmitter 16 , camera 14 and microphone 47 . Wire 50 can be used as the antenna for transmitter 16 . Preferably, a LED or another similar device is provided on transmitter 16 to indicate the level of power remaining in the battery, with the LED emitting a different colour as the battery is being gradually used up, for example green when the battery is new, switching towards a yellowish colour as the battery becomes moderately used up, and changing to a red light as the battery's life span comes to an end.
Preferably, joint 46 further carries a small microphone 47 therein, with a number of small holes 49 being provided through casing 46 for allowing the sound to reach microphone 47 . This allows apparatus 10 to catch sound waves from the speaker's mouth, and transmit them to remote amplifiers, preferably the portable hearing impaired persons' amplifiers.
In use, a speaker S, such as a teacher for hearing impaired children H as shown in FIG. 1 , wears headset frame 12 on her head, and adjusts the position of camera 14 relative to her mouth, by means of the rotation of dial 28 , of linear displacement of arm 40 inside dial 28 , and of rotation of camera 14 on joint 46 . The purpose of adjusting camera 14 is for its lens 48 to precisely target the mouth of speaker S and to be located exactly ahead of the speaker's mouth, so that the images caught by camera 14 are the images of at least the mouth and preferably also all the facial expressions of the speaker S. Other adjustment means can also be envisioned for the camera 14 , such as an articulated arm or any other suitable device. However, it is understood that once the positional adjustment of camera 14 is accomplished, the latter becomes rigidly supported by the headset frame 12 : that is to say, the camera will then be held in a motionless fashion relative to the headset frame during use.
These images and the sound waves from the microphone are transmitted through wire 50 into transmitter 16 , which codes the images into a proper signal, preferably being either one of radio waves, micro waves and infra-red waves, with the radio wave transmission being preferred over the other types of transmission. This wireless signal is transmitted by transmitter 16 , as an airborne signal and received by a number of remote receivers 18 located on the desks of the hearing impaired persons H. The receivers 18 decode the signal sent by transmitter 16 into images that can be visualised by proper visualising devices 20 , e.g. video monitor screens, computer screens, LED or LCD screens; and into sound that can be heard or partly heard with proper amplifier devices, such as the hearing impaired persons's hearing aids 52 or speakers 54 that are schematically shown in FIG. 1 . In the case of hearing aids 52 , it is understood that conventional hearing aids which include an audio signal receiver, could be used.
Thus, the hearing impaired persons H can read the lips of the speaker S at all times, even if she has her back turned to persons H, e.g. to write on a blackboard against the wall as suggested in FIG. 1 , due to the image of the speaker's mouth being reproduced on the visualising screens 20 provided for the hearing impaired persons. Also, the hearing impaired persons who are not completely deaf, will be able to partly hear the voice of the speaker simultaneously, either directly and/or through the audio signal carrying the second waves caught by microphone 47 . It is noted that most hearing impaired persons will in fact be able to at least partly hear certain sounds. For example, it is not an uncommon occurrence that hearing impaired persons are able to hear low frequency sounds, while not being able to hear higher frequency sounds; this hearing pathology can be seen especially with hearing-impaired children. Also, it is possible that hearing impaired persons are able to hear higher frequency sounds, while not being able to hear low frequency sounds; these last hearing problems often result from industrial-related machinery which works at low frequency. Generally, it is noted that the human hear can be sensitive to frequencies ranging from 20 Hz to 20000 Hz, and partial deafness often occurs only as applied to a portion of this frequency range for a particular individual. Thus, often with the help of amplifying hearing aid devices, the hearing impaired persons will listen to the speaker's voice and will be able to hear part of this speech, will accomplish lip reading directly on the speaker's face when the latter can be readily observed, and will use the visualising screens 20 when not able to either hear properly or to see the speaker's face and mouth to accomplish lip reading by direct eyesight.
Linking camera 14 to transmitter 16 by a wire 50 prevents transmitter 16 from having to be located on headset frame 12 proper, which would render same uncomfortably heavier. With wire 50 , transmitter 16 can thus be located on a remote location on the speaker S, for example attached to her belt as shown in FIG. 1 . It could also be inserted into a shirt pocket or the like. The purpose of this is to prevent this more heavy and cumbersome equipment from being supported by the speaker's head. Notwithstanding the load supported by the speaker's head, it would however be at least as convenient that the transmitter be located on the headset frame head-engaging portion, including a small antenna thereon, especially if a lighter power means and transmitter assembly is available.
FIG. 1 further shows that transmitter 16 comprises an enclosed battery section 16 a, which may be distinct therefrom, wherein a power supply battery may be inserted.
A best mode embodiment of the apparatus according to the invention would enclose all speaker components inside a head set assembly.
A more simple while still acceptable embodiment of apparatus would include the following components:
Student:
a) Video monitor—color Portavision 5 inches model, Radio Shack; or preferably, a LCD video screen, e.g. from Sony;
b) FM receiver—model 900 AMBBR, Microtech Electronics (San Clemente, Calif.);
2) Teacher:
a) transmitter—FM wavelength emitter, model Minilink 001823, Microtech Electronics, with on/off switch;
b) 2×6 volts batteries, 1.2 Amp. “Exaltor”;
c) micro colour solid state board camera with 4.4 mm diameter lens, and with digital processing, model UN411E ultra micro remote colour CCD camera from “Elmo”.
Obviously, the invention is not limited to such a given embodiment. The camera, in particular, may be one of many known miniature cameras sold on the market. The known technologies include optical fibre-based cameras, medical-type cameras (usually enclosed in a protective casing), or the above-mentioned solid state board camera. Other suitable image capturing devices such as CMOS imaging devices are also deemed to be included in the expression “camera”. Also, it is envisioned that the transmitter be included with the camera and the microphone in a single casing.
Throughout this specification, reference has been made to hearing impaired persons; it must be understood that partly or completely deaf persons are included in the expression “hearing impaired persons”.
It is an important feature of the present invention that transmission of the video and audio signals occur in real-time. As stated in the Background of the Invention section, real time is defined, according to a person skilled in the art of the present invention, as a maximum delay of 33 msec between the moment when the image is perceived and the moment when the sound is perceived by the hearing impaired person. Considering that the speaker will be emitting sound when speaking and that it is possible, or even likely, that the hearing-impaired persons will partly hear the speaker's voice directly (i.e. not through apparatus 10 ), then the transmission of the images and of the sounds captured through apparatus 10 must occur so that no more than 33 msec delay occurs between the image and sound capture, and the image and sound perception by the hearing-impaired person through apparatus 10 . This way, the images seen of the visualising screens 20 , the sounds heard through the amplifying hearing aids and the sounds heard directly from the speaker's mouth, will coincide, and any lip reading accomplished on the screens 20 will register with the voice of the speaker.
The audio signal is not problematic, since very little information is transferred therein relative to the video signal. Thus, it is easy to transmit the audio signal through apparatus 10 to the amplifying hearing aids within the 33 msec delay.
The video signal, however, is another matter, since image signals carry much more information. It is known that to capture an image and transmit it directly to a video screen, a delay of approximately 33 msec is required (i.e. 16.5 msec per half image). Thus, for the image transmission to remain within the required limit of 33 msec, the image must be transferred directly to the visualising screens 20 , without any software acting on the video signal for correcting the image, because software image correction is time-consuming, i.e. at least about 500 msec for a full image. Furthermore, signal compression through a MPEG compressor takes approximately 33 msec, as does the decompression through a MPEG decompressor, and thus compression and decompression of the image signal cannot occur. Therefore, image treatment is not an option, nor is compression of the image information, or else the image seen on the visualising device by the hearing-impaired person will be sufficiently offset relative to the voice partly heard from the speaker directly through class or through a hearing aid, for the hearing-impaired person to notice this offset. Reconciling the image seen on the screen and the speaker's voice can then become very difficult, and consequently trying to understand the speech becomes confusing and a difficult, if not impossible, task.
Thus, in the present specification, when it is stated that real-time transmission of the images occurs, it is understood that the images of the speaker's mouth and face are displayed on the visualising screens 20 within a 33 msec delay. With the actual technology, this means that no image treatment will occur, such as image correction software to correct the distortion of the images caught by the camera, or compression or decompression of the image through devices such as MPEG compressors and decompressors.
According to a preferred embodiment of the invention, transmitter 16 includes a video transmitter and an audio transmitter, each distinct from the other. Thus, the audio signal and the video signal are distinctly transmitted to the receivers 18 . Preferably, the video signal is transmitted on a radio wave band located in the 902-928 MHz range and the audio signal is transmitted on a radio wave band located in the 72-76 MHz range, the latter being the usual band used for hearing aid devices—and thus the system of the present invention may be compatible with conventional hearing aid devices. This low frequency for the audio signal also has the advantage of providing a more stable carrier wave, which may travel further for a same power output and which will suffer less loss of its signal. Alternately, the video signal can also be transmitted at a frequency range of 2400.0 to 2483.5 MHz, and the audio signal can also be transmitted at a frequency range of 216 to 217 MHz.
The fact that the audio and video signals are transmitted on two different bands, helps prevent the sound signal from being interrupted or polluted by video signal irregularities. Indeed, it is important to note that the video image of the speaker's mouth on the visualising screen is only a fall-back option for the hearing impaired person, who will normally read the speaker's lips directly and who will possibly partly hear the speaker's voice. The image on the screen will only be used when the speaker's lips cannot be read directly, so the sound signal often becomes more important that the image itself for the hearing-impaired persons that are equipped with a hearing aid device linked to apparatus 10 . Thus, it is important that the sound signal be as clear as possible, and consequently the video image is transmitted on a different band than that of the sound signal.
It is further envisioned to use two or more redundant channels for the audio signal, from which the hearing-impaired person can choose according to the best reception.
It is noted that the transmitter and receiver of the present invention are substantially closely positioned relative to each other. Indeed, contrarily to video-conferencing devices such as the one disclosed in the above-mentioned prior art Bullister patent, the apparatus 10 according to the present invention is destined to be used in a single general area, for example a single student class. The speaker is located in front of the class with his or her transmitter, while the hearing impaired persons are seated in class at a distance with their receivers and visualising devices, with the wireless broadcast communication occurring between transmitter and receiver. This allows the system according to the present invention to use low-power transmitters, which have two very important advantages which bring about surprising and unexpected results:
1) They do not require compulsory government regulatory licenses for communication devices that are otherwise required for transmitters transmitting at higher power, these licenses being granted by a communication regulatory body in most countries, such as Canada and the United States. 2) They prevent different devices 10 according to the invention and used in a same building, e.g. in a school, from hampering one another's signals, due to the different signals which could overlap one another if more powerful transmitters were used.
The expression “low-power transmitter” includes transmitters emitting at a power which allows the air-borne wireless signal to be received in a close vicinity relative to the transmitter, e.g. in a same room or in an adjacent room, while not covering important distances. The preferred maximum field strength of the emissions originating from the transmitter of the present invention is as follows, to obviate the obligation to obtain a regulatory license according to North-American standards: 50 millivolts per meter for the video signal, and 80 millivolts per meter for the audio signal, with the measurements being taken at a distance of three meters from the transmitter. This transmitter power is enough for the purpose of transmitting the signals over short distances, e.g. in a same room or perhaps in an adjacent room at the most if little interference from the wall structure between the rooms exists, but no more than that.
Wired communication over longer distances is likely to be accomplished through a modem or the like transmitter element, with relatively much longer delays of transmission of the image, which would result in the image not being displayed in real-time. This is an important difference relative to known videoconferencing devices, which use wired communication since wireless broadcast communication would require licenses due to the large distances involved. Even in the invention disclosed in the above-mentioned Ono patent application, telephone technology is used for transmitting the data, even if radio-wave data transmission has been known and widely used for many decades.
To prevent video signal irregularities, the video transmission should be of the Double Side Band Amplitude Modulation (DSM-AM) type which substantially allows the carrier wave to be replicated or mirrored, with only the better wave received being kept for the display of the image. Alternately, the video signal can also be a numeric signal, a FM radio wave transmission, or any other suitable transmission mode.
Furthermore, a pre-emphasis is applied to the audio and video signals at the transmitter, and a de-emphasis is applied to the signals at the receiver, to help prevent undesirable noise on the signals.
An automatic gain control (AGC) circuit is preferably used to regularise the signal which is received by the receiver 18 , as known in the art.
All the above-mentioned signal regulators which aim to provide the best output signal as possible for the best sound and image reproduction for the hearing-impaired person, are rather important, especially considering that the wireless transmitter is mobile, and that the speaker can and often will move as he or she speaks. This is likely to result in interference over the broadcast airborne signals, especially considering that the system 10 according to the invention is likely to be used in a closed room, the surrounding walls and building structure then promoting wave reflection and consequently interference on the signal. Thus, the numerous methods used to correct this situation and provide a signal as clear as possible, especially for the sound signal, are very advantageous.
Moreover, it is envisionsed to combine to the hearing impaired person's receiver a computer with a voice recognition software, that could put the speaker's speech in writing for ulterior revision purposes. This would be advantageous in the case of hearing impaired students, who would not have to take notes themselves during class, and who could consequently concentrate on understanding the speech of the teacher through lip-reading, instead of having to take down notes. For the voice recognition software to work properly, the audio signal must be as clear as possible. It is also possible to have a speech recognition software which would use both the audio and video signal to provide a text output, with both signals then being cross-analysed by the software; both signals then need to be as clear as possible.
Any minor modifications brought to the present invention as described herein which do not extend beyond its scope, are considered to be included therein.
For example, although each student H in FIG. 1 is shown to have one receiver 18 and one visualising screen 20 on his desk, it is understood that a single receiver 18 could be provided for a number of visualising screens 20 , e.g. if all the visualising screens 20 were network-linked computer screens. Also, a single receiver could be linked to a single visualising means in the form of a screen, preferably a giant-sized screen, facing all hearing impaired persons H. Also, although much more cumbersome, copper or optic fiber wiring could be used to carry the signal from transmitter 16 to receiver 18 instead of airborne waves.
It is understood that the headset of the present invention could be modified to any other suitable desired configuration. Also, the camera support arm could be located on the right-hand side of the headset, rather than on the left-hand side as shown in the drawings.
Moreover, the apparatus described in the present disclosure can be of use for persons without any hearing disabilities, particularly for children and teenagers located too far away from a teacher and who will use lip reading as complementary means for understanding the conversation; this method helps to direct the student's attention on understanding the meaning of what is said, rather than solely directing his attention on hearing what is said. Also, the use of the present apparatus can be extended to drive-through type restaurants, where it is preferable to see the face of the restaurant employee speaking in addition to hearing his or her voice, when ordering food from a remote location outside the restaurant. | There is described a method for providing audio and visual communication between a speaker and at least one hearing impaired person. The method comprises the steps of providing the speaker with a headset frame having a camera attached thereto and positioned to capture images of the speaker's mouth; providing the hearing impaired person with a display; capturing continuous video images of the speaker's mouth using the camera; and transmitting the images in the real-time to the display for the hearing impaired person to view such that movement of the speaker's mouth coincides with sound emitted by the speaker. | 7 |
FIELD OF THE INVENTION
The present invention relates to a grinding pump, for pumping liquid containing solid and semi-solid matter, whereby the blades and impeller vanes of the pump rotor cooperate with stationary serrated liners within the housing structure so as to tear, shred, grind, pulverize and urge solid matter and the entrained liquid downstream.
BACKGROUND AND SUMMARY OF THE INVENTION
Grinding while pumping a mixture containing liquid and entrained solid and semi-solid matter is a concept which has been known and practiced. However, current grinding pumps only grind and pulverize matter at the upstream end of the grinding pump, in a region between the surface of a rotating comminutor and the interior surface of the grinding chamber. After the mixture has been shredded and pulverized, it is moved along to a pumping section where an impeller forces the liquid and the entrained matter out towards an outlet port. Despite the apparent success of these pumps in the industry, they are not very efficient. Notwithstanding the current methods and devices used in the industry, it is perceived that the efficiency of these pumps has not reached its full potential. Therefore the need exists for still further improvement in the efficiency of grinding pumps, by for example increasing the rate of flow of the liquid and the entrained matter as well as by decreasing the energy requirements as would be readily apparent from a reduction in the required operating rpms.
The object of the present invention is to provide an improved grinding pump capable of pumping liquids containing entrained solid and semi-solid matter, such as raw sewage and the like, while reducing energy requirements and increasing efficiency. The discovery underlying the present invention is the realization that by incorporating the use of serrated edges on the outer edges of the centrifugal pump impeller vanes in cooperation with a serrated interior surface, liquid containing entrained solid and semi-solid matter can also be shredded and pumped by the impeller vanes with less energy and higher efficiency. The discovery is contrary to commercially known prior art teachings that require substantially more energy, exhibit a low efficiency, and limit grinding to the comminutor. The present invention is therefore a substantial improvement as apparent in its efficiency rating of approximately 20%. For the purpose of this application, efficiency is defined as: ##EQU1##
Moreover, in order to achieve an efficiency of 20%, the present invention optimally operates in the range of 900-1200 rpms. Such an operating range is unlike other known commercially available grinding pumps which operate at a higher rpm and achieve a lower efficiency.
Accordingly, the present invention relates to a grinding pump for pumping liquids with entrained solid and semi-solid matter comprising: a housing structure having a chamber with a longitudinal axis, said chamber having an inlet port, an intermediate portion defined by an irregular wall surface of revolution, an eccentric portion having an irregular wall surface and an outlet port; a rotatable shaft disposed along said longitudinal axis within said chamber; a comminutor mounted on said shaft within the intermediate portion of said chamber for rotation with said shaft, said comminutor comprising, a helical blade mounted on said shaft and rotatable therewith, the outer edge of said blade being irregular and when rotating defining a complementary surface of revolution to said surface of revolution of said intermediate portion of said chamber wall and closely spaced therefrom, said blade and said surface of revolution defining means for cutting, grinding and urging said matter downstream; a centrifugal pump impeller including at least one vane, said impeller being mounted on said shaft and rotatable therewith, the impeller being located immediately downstream from said blade, and said vane having an irregular edge which when rotating defines a surface of revolution complementary to a portion of said eccentric portion of said chamber and being closely spaced therefrom, said vane and said portion of said eccentric portion of said chamber together defining a second means for cutting and grinding said matter. As used herein, the word "irregular" is not intended to be limited to randomly variable. It is the intention of the applicant that the expression "irregular edge" means an edge having a plurality of projections, that is non-linear and varies from the linear either in a regular periodic or random fashion. Included within the term irregular edge are projections such as saw toothed edges, square toothed edges and serrated edges whether the periodicity of the variations in such edges is constant or varying.
Preferably the irregular chamber wall is provided by an overlay or liner secured to said housing structure along the wall of said chamber, and said liner including one or more shredding liner segments having a surface which is complementary in shape to the surfaces of revolution defined by said comminutor and impeller when rotating. Means are provided for removably securing said liner within said chamber so as to preclude said liner from rotating within said chamber in response to rotation of said shaft; and means for rotating said shaft within said chamber, such as, for example, a motor are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention will be explained in further detail and in reference to the drawings, in which:
FIG. 1 is a perspective view of a grinding pump embodying the present invention;
FIG. 2 is a sectional view taken along the line 2--2 in FIG. 1;
FIG. 3 is a longitudinal sectional view of the grinding pump taken along the line 3--3 in FIG. 2;
FIG. 4 shows an exploded perspective view of a pre-chop blade, a comminutor and an impeller forming parts of the invention;
FIG. 5 is a plan view of one type of liner segment especially adapted for shredding;
FIG. 6 is a plan view of another type of liner segment perforated to permit ground slurry to pass therethrough;
FIG. 7 is a plan view of the type of liner segment shown in FIG. 6, wherein the perforations are uniform and extend substantially throughout the length of the liner segment;
FIG. 8 is a view like FIG. 7, wherein the perforations are of varying size; and
FIG. 9 is a plan view of yet another liner segment, without perforations or serrations;
FIG. 10 is a sectional view taken along the lines 10--10 in FIG. 3
DESCRIPTION OF THE PREFERRED EMBODIMENT
A grinding pump assembly which is the subject of this invention, is shown in FIGS. 1 and 3 and is generally designated by the reference numeral 10. The grinding pump assembly 10 includes a housing structure 12 having a chamber 14 with an inlet port 16, an intermediate portion 18, an eccentric portion 20 and an outlet port 22. Liquid containing solid and semi-solid matter, such as raw sewage, which includes grindable matter entrained in water, hereinafter referred to as a slurry, is introduced at the inlet port 16 which preferably is frusto-conical with the diameter at the inlet opening 24 relatively smaller than that found at the downstream end of said inlet port 16. An increase in the inlet port 16 diameter in the downstream direction is preferred in order to pre-rotate the slurry as well as to prevent the backwashing thereof.
A shaft 26 is disposed along the longitudinal axis of chamber 14 and is supported for rotation within the chamber 14 by a bearing 27. Mounted on said shaft 26 for rotation therewith is a rotor 28 including a comminutor 30 and a centrifugal impeller 32, which are preferably integrally formed. The comminutor 30 is made of one or more helical blades 34, preferably three in number, and the impeller includes one or more vanes 36, preferably six in number. While a prototype having three blades and three vanes has been made, it is expected that the use of three blades and six vanes may increase the efficiency of the device of the present invention. The number of helical blades 34 is preferably an integral multiple of the number of vanes 36 or, alternatively, the number of vanes 36 is preferably an integral multiple of the number of helical blades 34 (i.e., 3 blades to 3, 6 or 9 vanes, or 3 vanes to 3, 6 or 9 blades). In addition, the downstream end of each of the blades 34 preferably makes a smooth (i.e. unimpeded or continuous) transition to the upstream edge of one of said vanes 36. Such a design enhances the efficiency of the grinding pump. Preferably, when there are more than one blade or one vane, the blades and/or vanes are uniformly distributed around the comminutor 30 and impeller 32, respectively.
Preferably, although not necessarily, a pre-chop blade 38 is mounted on the end of the shaft 26 in the downstream end of the conical inlet 16 to pre-shred the solid and semi-solid matter before it is passed further downstream to the comminutor 30 and impeller 32. The pre-chop blade 38 is made preferably of stainless steel or any other rust resistant material, and shaped in a variety of known cutting patterns. Shaft 26 extends and is disposed longitudinally throughout the entire chamber from the downstream end of inlet 16 to beyond a rear wall plate 40 which defines the downstream end of chamber 14. The portion of the shaft 26 which extends through the rear wall plate 40 of the housing 12 preferably is connected to a coupling 42 which is in turn driven by a rotating drive means such as an electric motor 44.
In accordance with the invention, the comminutor blades 34 are provided with irregular edge projections, for cutting, shredding, tearing, grinding and pulverizing. The chamber wall defining the intermediate portion 18 and the eccentric portion 20 is shaped complementarily to and closely spaced from the surface of revolution defined by the comminutor blades 34 and the impeller vanes 36 as they rotate with shaft 26. That is, the chamber wall surface is irregular. This establishes a highly effective grinding, shredding and cutting zone for reducing the particular size of the solid and semi-solid matter in the slurry as it is moved through the chamber in a manner to be described hereunder. In effecting this structure, it is preferred that the interior surface of the housing structure 12 is lined with liner segments, some perforated, some irregular or serrated, and some possibly smooth, or some combination of these options. One or more shredding liner segments 46 have an irregular surface for mating with the similarly shaped edges of the blades 34 and vanes 36. Operationally, however, the shredding liner segments 46 and the cutting edges of the comminutor blades 34 and impeller vanes 36 must be spaced apart to form a gap so as to permit the vanes 36 and the blades 34 to rotate and allow the slurry to flow downstream. Although different gap sizes may be used, it is to be recognized that such variations will affect the pressure head vs. flow performance characteristics and the efficiency of the pump 10. Preferably, the spacing between the comminutor blade surface 34 and the shredding liner segments 46 should be approximately 0.79 mm (1/32").
In order to further enhance the flow and thereby the efficiency of the pump, it is preferred that the chamber wall liner also include one or more discharge liner segments 48 and said discharge liner segments 48 have a plurality of apertures 50 so as to function as a screening/filtering plate. The apertures 50 on the discharge liner segments 48 may be disposed throughout the surface of the liner segment 48, although it is preferred that the apertures 50 be located primarily at substantially the downstream end of the chamber at the eccentric portion 20 of the housing chamber 14. In the preferred embodiment, the diameter of the apertures 50 is uniform and the apertures 50 are preferably positioned over the eccentric portion 20 of the chamber, although the apertures 50 can be provided throughout the entire surface of the discharge liner segment 48. (See FIGS. 6, 7 and 8.) In addition, the aperture sizes can vary and the apertures 50 may extend throughout the surface of the liner segment (see FIGS. 7 and 8). Although not shown in FIG. 3, discharge liner segments 48 having apertures throughout their entire surface require that there exist a space between the liners and the interior surface of the intermediate portion 18 so as to accommodate the outflow of the mixture at the upstream end.
While the shredding liner segments 46 have a serrated or toothed surface, the discharge liner segments 48 are presently contemplated as having smooth surfaces confronting rotor 28, even if only the portion confronting the impeller 32 is perforated. Of course, if desired, the discharge liners 48 could be both serrated and perforated throughout, or partly serrated and partly perforated or partly just serrated and the remainder serrated and perforated. In addition, the present invention can employ the use of plain liner segments 52 having a relatively smooth surface confronting the rotor 28 and which is therefore comparable in shape to the discharge liner segments 48 but without the perforations. The plain liner segments 52 provide a stabilizing zone for the entrained matter as it is ground by the action of the comminutor blades 34 and the impeller vanes 36 in cooperation with shredding liner segments 46.
As presently contemplated, the chamber wall lining is formed of shredding liner segments 46, discharge liner segments 48 and plain liner segments 52 together. For example, they may be alternated around the chamber wall or some other pattern of them may be employed. However, in the presently preferred embodiment, there are twelve liner segments disposed to define the liner for the interior chamber wall, each of the liner segments 46, 48 and 52 occupying approximately 30 degrees of the 360 degree circumference, and arranged in a sequence of discharge segment, shredding segment, plain segment and shredding segment, repeated three times. For example if the first discharge liner segment 48 is located at the six o'clock position and the above referenced pattern is followed in a clockwise direction, the second shredding liner segment of the first group is disposed at the nine o'clock position. A second group follows the first group so that the discharge segment of the second group is located at the 10 o'clock position. The discharge segment starting the third group would start at 2 o'clock. Of course, the entire pattern can be angularly shifted relative to the housing without effecting the presently preferred embodiment of the invention.
In order to hold the shredding, discharge, and plain liner segments 46, 48 and 52 in place within the interior of the housing structure 12, it is preferred that a circumferential groove 54 be provided on the rear wall plate 40 behind a back plate 56, which groove is capable of mating with the ends of said liner segments 46, 48 and 52 such that said liner segments can be positioned parallel to and aligned with the longitudinal axis of the shaft. At the inlet end 16 of the housing structure 12, a retaining liner ring 58 is placed between the inlet port 16 and the intermediate portion 18 of the housing structure 12. On the downstream surface of the retaining liner ring 58, there is a pin 60 projecting downstream and parallel to the longitudinal axis of the shaft 26 which mates with a hole 62 in the adjacent end of either a discharge liner segment 48, shredding liner segment 46 or a plain liner segment 52 while at the other end, said liners engage in a form-lock manner with the circumferential groove 54 of the rear wall plate 40. While the above structure will secure the liners 46, 48 and 52 in place as well as preclude rotation of the liners 46, 48 and 52 within the housing structure 12 and is preferred, other structures for removably locking the liner segments in place may be employed without departing from this invention.
In addition, it is preferable that said liners 46, 48 and 52 be segmented and have a hole mateable with said pin at either end so that said liners can be made reversible and replaceable. Experience has taught that the serrations on said liners positioned upstream experience a greater degree of abrasion than those found downstream. Therefore, in order to optimize the grinding efficiency when the upstream portion becomes worn, the shredding liners 46 may be reversed to place the comparatively unworn ends upstream and thus improve the effectiveness of the grinding pump. Moreover, to further enhance the abrasion resistance of the shredding liners 46 as well as the serrations found on the helical blades 34 and the vanes 36, a coating of boron chrome may be placed on the cutting edges.
In operation, after the slurry enters the inlet port 16 of the housing structure 12 under the urging of the helical comminutor 30 and the centrifugal pump including impeller 32, and has been preshredded by the pre-chop blade 38, the slurry is urged downstream towards the comminutor 30 and the centrifugal impeller 32 where additional grinding and shredding will take place. The irregular edges of the helical blades 34 in cooperation with the shredding liners 46 grind and shred the slurry, while imparting a spiralling effect on the slurry, forcing it downstream and towards the periphery of the intermediate portion 18 of the housing structure 12. After passing by the helical blades 34, the slurry encounters the irregular edges of the impeller vanes 36 which also grind and shred the slurry as well as urge the slurry against the surface of the liner segments so as to pass through the apertures of the discharge liners and into the eccentric portion 20. Once having entered the eccentric portion 20, the slurry will travel towards the outlet port 22.
The inner surface of the eccentric portion 20 and the outer surface of the 12 liners create a passageway 64 which is cross-sectionally narrower at the bottom (six o'clock position) than it is at the two o'clock and ten o'clock positions (see FIG. 10). The change in cross-sectional areas serves to minimize the pressure difference between the bottom of the eccentric portion 20 and the region in proximity to the outlet port 22. As the slurry is forced out, for example, in the embodiment wherein the discharge liners are located at the six, ten and two o'clock positions, it exits the discharge liner segment at the six o'clock position with a velocity which diminishes as the mixture travels towards the outlet port 22. By arranging additional discharge liners at the ten and two o'clock positions, the slurry forced out through the above discharge liners, minimize the pressure loss between the top and bottom portions of the eccentric chamber.
In its preferred embodiment, the present invention operates in the range of 900-1200 rpms, although the present invention is fully capable of operating at speeds greater than 2000 rpms if desired. A higher operating speed, however, is unnecessary in light of the present invention's 20% efficiency.
While the invention has been described in terms of pumping sewage, it will be recognized that this device may also be employed to advantage in other applications where slurries are to be pumped, such as, for example, waste water from a pulp or paper mill which usually has fiber entrained therein.
It should be understood that the preferred embodiments and examples described are for illustrative purposes only and are not to be construed as limiting the scope of the present invention which is properly delineated only in the appended claims. | A grinding pump for pumping liquid containing solid and semi-solid matter having an improved efficiency and which requires a lower operating rpm while exhibiting an increased flow rate. The pump includes: a housing having a chamber; a shaft rotatably disposed within the housing, a comminutor on the shaft within the housing and having a helical blade, and an impeller having a vane; and a shredding liner secured to the housing structure in the chamber, so as to cooperate with the comminutor and impeller vane in shredding and pulverizing the matter. | 5 |
BACKGROUND
[0001] In many jurisdictions, off-duty police officers are required or permitted to carry a handgun that is in some way concealed from the view of others who may be in proximity to the officers. This is particularly important to those who may be working “under cover.” Many of these officers may also wish to carry a concealed handgun in addition to the service weapon normally worn whale on duty. In addition, many states have enacted “right to carry” laws that permit a resident to carry a concealed handgun providing the resident has taken a prescribed handgun safety course, has no criminal record, has no outstanding restraining orders imposed by a court of law, and has passed a background check. Many states may not permit persons within the state to openly carry a handgun in public places.
[0002] Concealing a handgun may be accomplished by hiding it from view of others within a person's clothing or garments. While being hidden beneath layers of clothing may accomplish concealment, it may also make it difficult for the user to access the handgun expeditiously when confronted by danger. An example of this method of concealment is a shoulder holster carried beneath an armpit and covered with a jacket. Another example is a holster attached to a lower part of a leg. Both of these examples may limit the speed with which a user can access the handgun. Even a holster worn inside a belt and pant waist may require some form of clothing to conceal the presence of a handgun, such as having to wear a shirt tail outside the pants, which may make quick access difficult.
[0003] Another method of concealing a handgun is to enclose it within an article that appears to be something other than a holster for a handgun. The exterior façade may appear to be a carrying case for a mobile phone or pager. It may also be a fanny pack, bi-fold wallet or pouch used when hiking or participating in similar sporting activities. These implementations typically rely on mechanical snaps, zippers and hook-and-loop type fasteners to close an opening used to access the firearm, and usually require the use of two hands or extensive movements of the hands and arms. These enclosing devices may impede access to a handgun when it becomes necessary to access it quickly.
[0004] Although many new handgun designs have been dramatically reduced in size, thereby making it easier to conceal, prior art methods described in available literature for concealing a handgun are still encumbered with poor concealment and difficulty of quick access when required.
SUMMARY
[0005] The following disclosure describes a handgun holster for concealed carry that relies on a façade of a cell phone, or a cell phone case with spring-loaded hinges securing moveable panels. It is a compact design that can be worn on the street when dressed in casual clothes or in an office setting when wearing more formal work clothes without drawing attention to the fact that the wearer is carrying a handgun. Although it may rely on a snap or hook-and-loop material, another embodiment using a single magnetic latch on the front or rear edge of a spring-loaded panel is advantageous for rapid acquisition of the handgun. Under this embodiment, springs may be released for providing opening of the holster by simply pressing inward on a side panel, which breaks the magnetic force holding the release springs.
[0006] The handgun holster is designed to fit inside the waistband in front of a side pocket close to a draw hand. Being free of material, zippers or straps, it enables a clean grip of the handgun yet allows for quick access that may be accomplished with the flip of a finger. Access is provided whether a user is standing or sitting, allowing ready access even while sitting in a vehicle.
[0007] The holster includes spring-loaded hinged panels that appear to be a cell phone case when closed. When unlatched, the hinged panels spring open to be flush against the body of the user, allowing unimpeded access to the handgun held within the holster pocket, wherein the handgun may be quickly drawn and ready for use. Access is provided with minimal movement of an arm, a hand or even just a finger. A waistband clip may be provided to safely secure the holster containing a handgun inside the waistband of a user while holding the holster securely in place while the gun is withdrawn.
[0008] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other features, aspects and advantages of the present invention will become better understood with regard to the following description and accompanying drawings wherein:
[0010] FIG. 1 is a perspective view of an embodiment of a handgun holster closed for concealed carry;
[0011] FIG. 2A-FIG . 2 D illustrates sequential snapshots of an embodiment of a handgun holster opening;
[0012] FIG. 3 is a perspective view of an embodiment of a handgun holster in a completely open state;
[0013] FIG. 4 illustrates embodiments of a back side of a handgun holster; and
[0014] FIG. 5 illustrates an alternate placement of one of the panels.
DETAILED DESCRIPTION
[0015] For reference purposes, Table 1 below provides reference designator identification for the components of embodiment of the disclosed holster.
[0000]
TABLE 1
REFERENCE DESIGNATOR IDENTIFICATION
100
View of Holster in a Stand-Alone and Attached Configuration
110
Hinged Butt Panel
120
Hinged Top Panel
130
Hinged Front Panel
140
Fixed Hammer Panel
150
Waistband Clip
160
Holster Pocket
180
Back Panel First Version
185
Back Panel Second Version
190
Garment
195
Waistband or Belt
200
Sequential Snapshot Views of a Holster Opening
210
Second Fastening Means
215
First Fastening Means
220
First Actuating Hinge
230
Second Actuating Hinge
300
Perspective View of Completely Open Holster
310
Third Actuating Hinge
320
Outline of a Handgun Butte, Handgrip and Hammer
400
Backside View of Handgun Holster
410
Fasteners
500
View of a Second Holster Embodiment
[0016] The detailed description is directed to a handgun holster apparatus for a person desiring to carry a handgun concealed from view of others. FIG. 1 is a perspective view 100 of an embodiment of a handgun holster closed for concealed carry. FIG. 1A shows the holster in a stand-alone configuration. It includes a hinged butt panel 110 (in reference to the side of the holster where the butt of the gun's handle is positioned), a hinged top panel 120 and a hinged front panel 130 . These hinged panels are preferably spring-loaded for fast access to an enclosed handgun when released. A fixed hammer panel 140 (in reference to the side of the holster where the hammer of the gun is positioned) is rigidly positioned to a back panel of the holster 180 (shown in FIG. 2E ) opposite the hinged front panel 130 . A holster pocket 160 is provided to hold a handgun securely until deployment, and is attached to the back panel 180 as shown in FIG. 4 . A waistband clip 150 is provided to secure the holster to a waistband or belt 195 of a garment 190 . FIG. 1B shows the holster attached by a waistband clip 150 to a waistband or belt of a garment 190 worn by an individual.
[0017] FIG. 2A-FIG . 2 E illustrates sequential snapshots of a butt-side panel 110 view. Not shown is a handgun positioned within the holster pocket 160 shown in FIG. 1A . The hinged front panel 130 is secured in a closed position by a first fastening means 215 attached to the hinged front panel 130 and a second fastening means 210 attached to the hinged butt panel 110 . The hinged front panel 130 is attached to the hinged top panel 120 by a first spring-actuated hinge 220 . Similarly, the hinged top panel 120 is attached to the back panel 180 by a second spring-actuated hinge 230 .
[0018] FIG. 2B and FIG. 2C shows progressive snapshots of the hinged front panel 130 and the hinged top panel 120 opening under the force of the first and second spring-actuated hinges 220 , 230 when the user releases the fastening means 210 , 215 with a press or pull of a finger. The front panel 130 rotates about an axis of the first actuating hinge 220 and the top panel 120 rotates about the axis of the second actuating hinge 230 .
[0019] FIG. 2D illustrates a butt-side panel 110 view of the holster fully opened, with the first and second spring-actuated hinges 220 , 230 shown in a fully opened position. The sequence of snapshots shown between FIG. 2A and FIG. 2D occurs very quickly under force of the first and second spring-actuated hinges 220 , 230 when the fastening means 210 , 215 is released by the user. The configuration shown in FIG. 2D enables a user to quickly access a handgun cradled in the holster pocket. FIG. 2E illustrates a hammer side panel 140 view of the holster fully opened, with the first and second spring-actuated hinges 220 , 230 shown in a fully opened position.
[0020] FIG. 3 is a perspective view of an embodiment of a handgun holster in a completely open state or accessible configuration. FIG. 3A shows the holster in a stand-alone and open configuration. It includes a hinged butt panel 110 , a hinged top panel 120 and a hinged front panel 130 . As noted above, these hinged panels are preferably spring-loaded for fast access to an enclosed handgun when fastening means 210 , 215 is released. A fixed hammer panel 140 may be rigidly positioned to a back panel of the holster 180 , or may be connected by a spring-actuated hinge to the back panel 180 , similar to a third spring-actuated hinge 310 connecting the butt panel 110 to the back panel 180 . A holster pocket 160 is provided to hold a handgun when the holster is in a closed or concealed configuration as shown in FIG. 1A and FIG. 1B , and an open or accessible configuration, as shown in FIG. 3A and FIG. 3B . A waistband clip 150 is provided to secure the holster to a waistband or belt 195 of a garment 190 , as shown in FIG. 3B . FIG. 3B shows the holster attached by a waistband clip 150 to a waistband or belt of a garment 190 worn by an individual. FIG. 3A also shows the first fastening means 215 , the second fastening means 210 and the first, second and third spring-actuated hinges 220 , 230 , 310 . Similarly to the operation of the spring-actuated hinges 220 , 230 described above, when the user releases the first fastening means 215 and second fastening means 210 , the third spring-actuated hinge 310 causes the hinged butt panel 110 to quickly swing open. This action coupled with the simultaneous actions of panels 130 , 120 , as described above, enables access to an enclosed handgun. The fastening means may be a snap fastener, hook-and-loop fastener or a magnetic fastener. For reference purposes, the outline 320 of the butt, the handgrip and the hammer portion of a handgun is shown as dashed lines in FIG. 3B .
[0021] FIG. 4 illustrates embodiments of a back side 400 of a handgun holster. The purpose of the back side is to rigidly position the connecting second and third hinges 230 , 310 and top portion of a holster pocket 160 , while conforming to the shape of the body of a user and protecting user's clothing from gun oil. FIG. 4A illustrates a configuration whereby the back panel 180 and the holster pocket 160 are separate pieces held together by fasteners 410 . The back panel 180 is rigid but the holster pocket 160 is typically fabricated from leather, fabric or extruded synthetic material. FIG. 49 illustrate a second embodiment of a back panel 185 that is a single fabricated piece of leather or synthetic material. The second embodiment of the back panel 185 may also be an integral part of a completely extruded handgun holster for concealed carry.
[0022] FIG. 5 illustrates another embodiment of the holster, whereby the butt panel 110 may be attached via a third spring-actuated hinge 310 to the front panel 130 instead of to the back panel 180 . This may provide for smoother motion of releasing the fastened means while continuing to move the hand toward the pistol because the user's finger would not have to reverse direction to move out of the way of the swinging panel after releasing the fastening means. The butt panel 110 would then immediately begin springing upward and away from the hand as it opens, as shown in FIG. 5 .
[0023] Although the subject matter has been described in language specific to structural features and methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. | A holster for concealed handgun carry that relies on the façade of a cell phone or cell phone case, and which relies on actuated hinges for securing moveable panels. Spring loaded hinges may be used for providing opening of the hinged panels of the holster, providing access by the wearer to the handgun contained within the holster. Latching of a closed configuration may be accomplished by a snap, hook and loop fasteners and magnetic fasteners. Access to a handgun contained within the holster may be accomplished with minimal movement of an arm, hand or finger. | 5 |
This invention relates generally to precision moulding or finishing machines of the type having an input mould carrier and a finishing mould carrier mounted on parallel axes for synchronized continuous motion along an endless path, input moulds mounted on said input mould carrier, each input mould having an input mould face, finishing moulds mounted on a finishing mould carrier, each finishing mould having a finishing mould face. In particular, this invention relates to an improved transfer system for transferring moulding materials such as preforms from the input carrier to and around on the finishing carrier and through the point of final discharge of the finished product said transfer system comprising a multiplicity of transfer moulds, each transfer mould having a transfer mould face adapted for cooperation with the input mould face of an input mould and with the finishing mould face of a finishing mould, each transfer mould being mounted on a transfer mould assembly, transfer mould carriers located sequentially with said finishing mould carrier, and mounted on parallel axes with said finishing mould carrier and said input mould carrier for synchronized continuous travel therewith, and an improved orienting control system, said transfer mould assemblies being adapted for rotation about an orientation axis and for mounting rotatably about said axis for transfer sequentially to support on releaseable mounts moveably mounted on the transporting carriers along an endless path around an enclosure along the finishing section of said finishing carrier and back and forth between said finishing carrier and said input carrier on said transfer mould carriers.
In prior devices for producing fully finished moulded articles from fibrous pulps the moulding machines currently in operation comprise a number of different pressing stations in fixed positions spaced at circumferential intervals about the axis of rotation of a carrier, and each of the moulds mounted on the carrier is indexed and presented sequentially, together with the contained product, to a different matching mould at each of the pressing stations. A number of patents have been issued describing various moulding machines including:
U.S. Pat. No. 2,163,585 (Chaplin)
U.S. Pat. No. 2,760,412 (Lemieux)
U.S. Pat. No. 2,859,669 (Leitzel)
U.S. Pat. No. 3,190,791 (Potter)
U.S. Pat. No. 3,320,120 (Randall)
U.S. Pat. No. 3,477,908 (Danille)
U.S. Pat. No. 3,661,707 (Emery et al)
An improved combination of the travel paths of the individual moulds in a matched pair of moulds for more precise mating and separating of said moulds in continuous motion is described in U.S. Pat. No. 3,661,707 issued to Roy W. Emery and John R. Emery.
The present invention is an improvement over prior art machines.
In the moulding machine of the present invention, each transfer mould element, together with its contained product, is mated sequentially with one matching finishing mould element mounted on a continuously moving finishing mould carrier, and the moulded product remains within the same matching pair of moulds in the drying and finishing process throughout their travel around on said finishing mould carrier and until the transfer mould assembly and its contained product are transferred therefrom.
The transfer system of this invention comprises a multiplicity of transfer mould assemblies each having a series of cam followers mounted circumferentially about the supporting shaft at intervals, and a series of cam tracks by means of which the transfer mould assemblies are controlled and oriented throughout their travel path between an input carrier and a finishing carrier, the number and spacing of the cam followers being adapted to provide for complete rotation through 180 degrees in either direction in relation to the main shaft of the supporting rotary carrier, as required for the transfer of the moulded products from the input carrier to the finishing carrier and thence to the point of final discharge. According to one aspect of the present invention, there is provided a moulding machine for moulding fibrous material such as wood pulp to form moulded items comprising an input carrier and a finishing carrier each mounted for continuous synchronized rotation about parallel axes, input moulds mounted on said input carrier, each input mould having an input mould face, finishing moulds mounted on said finishing carrier, each finishing mould having a finishing mould face, transfer moulds which are mounted in a releasable transfer mould assembly for transfer sequentially from one carrier to the next succeeding carrier in its travel path, each transfer mould having a transfer mould face adapted to cooperate with the input mould face of the input moulds and also with the finishing mould face of the finishing moulds to form mould cavities therebetween in use, each transfer mould having an axis of rotation about which it is rotatable to reorient its transfer mould face with respect to the input and finishing mould faces as required in use, transporting means for transporting said transfer moulds along an endless path which extends around an enclosure, said transporting means comprising a first mould reorienting means serially arranged between the input carrier and the finishing carrier to cause each transfer mould to rotate about its axis of rotation through 180 degrees from a first orientation in which the transfer mould face is directed outwardly of said enclosure when in engagement with said input mould carrier to a second orientation in which the transfer mould face is directed inwardly of said enclosure when in engagement with said finishing mould carrier when transferring a moulded item from the input carrier to the finishing carrier, a second mould reorienting means serially arranged between the finishing carrier and said input carrier to cause each transfer mould to rotate about its axis of rotation through 180 degrees from said second orientation to a third orientation in which the transfer mould face is directed outwardly of said enclosure so as to be correctly oriented for re-engagement with said input moulds of said input carrier.
The present invention further provides, in a moulding or finishing machine for moulding or finishing material such as wood pulp to form moulded items, the machine having an input carrier which has a plurality of input moulds mounted thereon, a finishing carrier which has a plurality of finishing moulds mounted thereon and a plurality of transfer moulds adapted to cooperate with the input and finishing moulds to transfer a preform from each input mould to a finishing mould and to remove a finished moulded item from its finishing mould and discharge the finished moulded items into a discharge station, the improvements of; transfer means located between the input carrier and the finishing carrier, the transfer means being operable to sequentially detach each transfer mould from the finishing carrier and thereby release each transfer mould from the finishing mould with which it is mated when attached to the finishing carrier, transport each detached mould away from the finishing carrier into and out of engagement with an input mould of the input carrier and reattach it to the finishing carrier in engagement with a second finishing mould, and means for guiding the movement of and orienting each detached transfer mould into and out of accurate transfer alignment with one of the input moulds and then into and out of accurate transfer alignment with one of the finishing moulds as the detached transfer mould is transported by transfer means. The input carrier and the finishing carrier are mounted on parallel axes for continuous synchronized motion. Each transfer mould is mounted on a transfer mould assembly having an axis of rotation about which it is fully rotatable to orient each transfer mould to face inwardly when cooperating with the finishing mould faces of the finishing moulds on the finishing mould carrier, then reorient the transfer mould face to face outwardly in its travel around on the transfer mould carriers and through a discharge station where the finished products are discharged from the transfer moulds and through an input station where the moulding materials are transferred from the input moulds to the transfer moulds, then reorienting again through 180 degrees in its continuing travel on the transfer carrier towards the finishing carrier, the transfer mould assembly being arranged for sequential transfer to support on releasable mountings on each transporting carrier as it proceeds in continuous motion along an endless path which extends around an enclosure, the endless path comprising travel along a portion of the pressing section of the finishing carrier where the transfer moulds and the finishing moulds are mated together in a pressing function, followed by travel while supported releasably and rotatably on one or more sequentially arranged transfer carriers which extend the path of travel through the point of final product discharge where the finished products are removed from the transfer moulds and through the input station where the empty transfer moulds cooperate with the input moulds to receive moulding material therefrom and thence onward to cooperation of the transfer moulds with the finishing moulds by means of which each individual mould is mated with one matching finishing mould and supported thereon in a pressing operation throughout their travel around together on the finishing carrier. The system of control and orientation of a precise travel pattern provides a shaft at each end of each of the transfer mould assemblies, the shafts beings located along the axis of rotation of the transfer mould assemblies and each of the shafts having mounted thereon a pair of rollers, one of each pair of rollers providing rotatable support in releasable mounts on each of the transporting transfer carriers, while the other one of each pair of the rollers serves as a guide roller, each of the guide rollers travelling along a continuous series of guide tracks whereby to guide the transfer moulds along an optimum travel path for mating in cyclical order and with maximum precision each of the transfer moulds with its matching input mould on the input carrier and with its matching finishing mould on the finishing carrier. Each of the shafts mounted at the ends of each transfer mould assembly is mounted at its outer end with an orienting lever arm, each of the lever arms being fitted with a multiplicity of cam rollers each of which rollers travels intermittently and alternately along cam roller tracks while the transfer mould assemblies are transported sequentially on each of the transporting transfer carriers, the cam rollers cooperating with the cam tracks to provide a precisely controlled optimum continuous orientation program for the transfer moulds as they travel into and out of cooperation alternately with the input moulds on the input mould carrier and the finishing moulds on the finishing mould carrier. The input mould carrier is a rotary input mould carrier wheel and the finishing mould carrier is a rotary finishing mould carrier wheel, each mounted on parallel axes for continuous synchronized motion. The improved transport and orientation system for the transfer mould assemblies may include a transport system for transporting the transfer mould assemblies and their contained transfer moulds back and forth between the input mould carrier wheel and the finishing mould carrier wheel is comprised of a first rotary transfer carrier wheel, a second rotary transfer carrier wheel and a third rotary transfer carrier wheel, the transfer carrier wheels being mounted on axes parallel with each other and with the axes of the input mould carrier wheel and the finishing mould carrier wheel for synchronized continuous motion controlled by a gear train and sequentially arranged to form an endless travel path around an enclosure, the endless path passing continuously along adjoining portions of the circumferences of each of the three rotary transfer carrier wheels and of the finishing mould carrier wheel and making tangential contact between the second transfer carrier wheel and the input carrier wheel, each of the transfer carrier wheels having a multiplicity of radially movable releasable mountings thereon, each of the mountings having a notch to receive one of the pair of shaft mounted rollers at each end of each transfer mould assembly, each of the mountings being urged radially outwardly of the central shafts of the transfer carrier wheels by coiled springs or other means, but limited and retained in its outwardly movement by the resistance of the other roller of the shaft mounted pair rolling along on a guide track located outwardly thereof, the mounting on each of the transfer carrier wheels beings located in parallel but separate planes with the mountings of the next consecutive transfer carrier wheel, and in alternating planes with the guide roller tracks, so that the two rollers of each pair of the shaft mounted rollers may alternate in their functions as supporting rollers and guide rollers as the related transfer mould assembly is transferred from one carrier to another. The orienting system is comprised of:
(i) orienting lever arms fitted on the ends of each of the two shafts mounted at the opposite ends of each transfer mould assembly, with three cam rollers mounted on the outer side of the lever arm at one end of the transfer mould assembly and two cam rollers mounted on the outer side of the lever arm at the other end, the five cam rollers being circumferentially spaced about the axis of rotation of the transfer mould assembly,
(ii) a series of arcuate cam track sections located alongside that portion of its travel path where the transfer mould assemblies are transported on the transfer carrier wheels to cooperate sequentially with one or the other of the five cam rollers at one end or the other of the transfer mould assemblies, and
(iii) in the pressing system where the finishing moulds are supported on radially movable mountings on the finishing mould carrier wheel, the mountings being urged outwardly of the rotary axis of the finishing mould carrier wheel, slotted guide notches are located adjacent each end of each of the finishing mould mountings to receive the guide rollers mounted on the shafts at each end of the transfer mould assemblies, a set of four locking pins mounted on each of the transfer mould assemblies arranged to cooperate with locking devices movably mounted on the finishing mould carrier wheel, the locking devices being automatically operated to lock each of the transfer mould assemblies in the pressing position as the transfer moulds are mated with the finishing moulds whereby to maintain the transfer moulds in the pressing position while resisting the radially outward force of the pressing action, and subsequently to unlock the transfer mould assemblies as the transfer moulds begin to be unmated from the finishing moulds, each of the transfer mould assemblies being guided in cyclical order into and out of the locking position by the action of the guide rollers travelling along on the guide tracks. The input mould carrier wheel is arranged to rotate into and out of a vat containing moulding materials and to form moulded preforms in the input moulds mounted thereon, a transport and orienting system as previously described is necessary for the transport and orientation of the transfer mould assemblies as they travel back and forth between the input mould carrier wheel and the finishing mould carrier wheel and around on the finishing mould carrier wheel.
The present invention further provides for an extended transport and orienting system comprised of first, second and third rotary transfer carrier wheels and a twin chain conveyor, all mounted on axes parallel with each other and with the axes of the input mould carrier wheel and the finishing mould carrier wheel, the first pair of sprocket wheels of the chain conveyor being located sequentially between the first rotary transfer carrier wheel and the second rotary transfer carrier wheel, a second pair of sprocket wheels being mounted on the shaft of the second rotary transfer carrier wheel, each of the twin chains of the chain conveyor having notched links therealong to form releasable mounts for conducting the transfer mould assemblies along the supporting tracks of the chain conveyor, two sets of three shaft mounted rollers each being provided, one at each end of each of the transfer mould assemblies, a first roller of each of the sets of three rollers being of smaller diameter for releasable mounting in notched links, a second roller of larger diameter in each of the sets of three rollers being arranged to roll along one of the tracks of the chain conveyor, thereby to retain the first roller in place in the notch of the notched link, the third roller of each of the sets travelling along or beside the tracks of the chain conveyor for transfer into the releasable mounts of the second rotary transfer carrier wheel.
The input mould carrier wheel is arranged to rotate in and out of a vat containing moulding materials, from which to form moulded preforms in the input moulds.
The input mould carrier is a rotary input mould carrier wheel and the finishing mould carrier is a rotary finishing mould carrier wheel, each mounted on parallel axes for continuous synchronized motion in an endless path. The improved transport and orienting system for transporting the transfer mould assemblies back and forth between the input mould carrier wheel and the finishing mould carrier wheel comprises:
(a) a rotary transfer carrier wheel mounted on an axis parallel to the axes of the input mould carrier wheel and the finishing mould carrier wheel for synchronized continuous motion controlled by a gear train and
(b) a twin chain conveyor with an endless travel path about a pair of sprockets mounted on the central shaft of the transfer carrier wheel and along arcuate chain guide tracks leading from the sprockets to the finishing mould carrier wheel and thence onward on continuing chain guide tracks mounted externally of the circumference of the finishing mould carrier wheel and thence returning along a second pair of arcuate chain guide tracks towards the pair of sprockets on the transfer carrier wheel and the orienting system previously described.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood after reference to the following detailed specification read in conjunction with the drawings wherein;
FIG. 1 is a side elevation of a moulding machine constructed in accordance with one embodiment of the present invention, and adapted to the discharge of the finished products by means of a vacuum pick-up system.
FIG. 2 is an end view at one end of a transfer mould assembly adapted to the moulding machine of FIG. 1.
FIG. 3 is an end view at the other end of the transfer mould assembly of FIG. 2.
FIG. 4 is a side view of the transfer mould assembly of FIG. 2.
FIG. 5 is an internal longitudinal vertical section of a portion of the machine of FIG. 1, showing in more detail the input carrier, the finishing carrier, the first, second and third transfer carrier, and the related vacuum pick-up discharge system. FIG. 6 is an end view of a transfer mould assembly mated with a finishing mould assembly, with the lever arm of the transfer mould assembly removed.
FIG. 7 is a diagram showing the valves of a transfer mould assembly and a transfer carrier mated together.
FIG. 8 is a diagram of the first, second and third transfer carriers of the machine of FIG. 1, with all of the moulds and the transfer mould assemblies removed, to show more clearly their relationship with each other and with the input carrier and the finishing carrier.
FIG. 9 is a transverse vertical section of the machine of FIG. 1
FIG. 10 is a diagram illustrating the gear train which synchronizes the rotary motions of the machine of FIG. 1
FIG. 11 is a diagram of the various cam tracks for use with the cam rollers and followers of machine of FIG. 1 for guiding and orienting the transfer mould assemblies in their travel path from the finishing carrier and through the discharge and input stations and back to their support on the finishing moulds of the finishing carrier.
FIG. 12 is a side elevation of a moulding machine constructed in a second embodiment, wherein the transport system has been extended by the addition of a chain conveyor to facilitate the discharge of the finished products by drop-off directly on to a belt conveyor.
FIG. 13 is an end view of one end of a transfer mould assembly showing an alternative and simplified cam follower arrangement made possible by the extended transport system of FIG. 12.
FIG. 14 is a diagram of the first, second and third transfer carriers of the machine of FIG. 12, showing the extended travel path of the transfer mould assemblies about a chain conveyor, and the location of the drop-off discharge point for the finished products.
FIG. 15 is a side view of a transfer mould assembly fitted with additional shaft mounted rollers for transport on the chain conveyor of the moulding machine of FIG. 12 as will be explained later.
FIG. 16 is a diagram illustrating the gear train of the machine of FIG. 12 mounted with a supplementary chain conveyor.
FIG. 17 is a plan view of a portion of one of the two carrier chains of the chain conveyor showing the relationship of said chain with the rollers mounted on the principal shafts of the transfer mould assembly of FIG. 15.
FIG. 18 is a side view of the chain of FIG. 17.
FIG. 19 is a diagram illustrating an alternative gear train of the machine of FIG. 12 using a chain conveyor which travels freely about the finishing carrier and externally of the circumference thereof, and then transports the transfer mould assemblies in cyclical order from the finishing carrier through the product discharge station, and through the preform input station at the input carrier, and thence onward to the finishing carrier, at which point the transfer mould mould assemblies are released and mated with the finishing moulds and are supported thereon in their travel path around the finishing carrier.
FIG. 20 is a side elevation of a moulding machine constructed in a third embodiment, comprising a simplified orientation program and a major extension of a chain conveyor serving as a supplementary transfer carrier and providing additional length of travel for alternate locations for discharge of the finished products, and for additional finishing functions such as printing and after drying. FIG. 21 is an internal longitudinal section of the moulding machine of FIG. 20 showing the extended travel path of the chain conveyor.
FIG. 22 is a diagram showing in more detail the relationship of the chain conveyor and one of it spockets with the input carrier, the first transfer carrier, and the finishing carrier, and also showing a typical valve connection between a transfer mould assembly and a transfer carrier. The arrangement of the transfer carrier 14 is similar and will not be described further here.
DETAILED DESCRIPTION
With reference to FIG. 1 of the drawings, the numeral 8 refers generally to a moulding machine constructed in accordance with an embodiment of the present invention. The moulding machine 8 comprises an input carrier 10, a finishing carrier 13, a first rotary transfer carrier 11, a second rotary transfer carrier 12, a third rotary transfer carrier 14 and a multiplicity of transfer mould assemblies 19. The input carrier 10 rotates through the forming vat 9, and acts as a vacuum former on which preform moulded items are formed in a well known manner.
Referring to FIG. 5 the first rotary transfer carrier 11 transfers the transfer mould assemblies 19 with their contained moulded preforms to the second rotary transfer carrier which in turn transfers the transfer mould assemblies and their contained preforms to support and travel around on the finishing carrier. The third rotary transfer carrier transfers the transfer mould assemblies 19 and the contained finished items from the finishing carrier to the first rotary carrier 11, which in turn carries the transfer mould assemblies 19 through the discharge point of cooperation with the vacuum pickup assembly 15 where the finished products 27 are discharged serially on the the belt conveyor 26. The operation of the vacuum pickup is well known in the industry, and will not be described here. The transfer mould assemblies 19, with the finished products 27 having been removed therefrom, continue around on the first transfer carrier 11 once again to the point of cooperation with the input moulds 40 on the input carrier 10. The finishing process being performed between the transfer moulds 41 and the finishing moulds 42 when mated on the finishing carrier 13 may comprise pressing a previously dried preform with one or both moulds heated to achieve permanent densification and a smoother surface, or pressing a wet moulded preform with unheated moulds to achieve partial densification, partial dewatering and a smoother surface, or pressing a wet moulded preform with one or both moulds heated to achieve improved densification, with partial dewatering by pressing and further drying by evaporation. Removal of moisture pressed or evaporated from the moulded product is effected by the application of vacuum internally of the moulds in a manner well known to the industry.
The input carrier 11 of the machien of FIG. 1 is an input mould carrier wheel comprising a rotary drum 124 mounted for rotation about shaft 20. In a wet forming operation the lower segment of said rotary drum extends into a pulp vat 9. A plurality of forming moulds 40 are mounted at circumferentially spaced intervals about the drum 124, and are arranged to pass sequentially through the vat 9. A gear wheel 30 is mounted on the shaft 20 and serves to drive the rotary drum 124 in synchronized rotation with the finishing carrier 13. The first transfer carrier 11 is mounted for rotation about shaft 21 in bearings supported on the frame 18. In the embodiment illustrated in FIG. 5 the second transfer carrier 12 is mounted for rotation on shaft 22 which is supported in bearings mounted on frame 18, and the third transfer carrier 14 is mounted for rotation on shaft 24 which is supported in bearings mounted on frame 18.
The input carrier 10 and the finishing carrier 13 are each supplied with facilities for the controlled application of vacuum and compressed air to each of the moulds which they support, the means of supply comprising connecting piping 64 leading from a rotary valve mounted on each of their principal shafts as shown in FIG. 6 and FIG. 8, in a manner which is well known in the industry and therefore will not be described here in detail. Vacuum and compressed air as required in use are supplied to the transfer moulds 41 while supported on the finishing moulds 42 of the finishing carrier 13 through the connecting valves 58a and 59 as shown in FIG. 6, and by connecting valves 58b and 459 as shown in FIG. 17 when supported on one of the transfer carriers 11, 12 or 14. The finishing carrier also has facilities for the controlled application of compressed air at a higher pressure level to a plurality of airmounts 66 through connecting piping 65.
The relationship of the radially moveable mounts 85 on transfer carrier 11 and 95 on transfer carriers 12 and 14 to each other and to the guide mounts 77 on the finishing carrier is shown in FIG. 8, the mounts 85 of transfer carrier 11 and the mounts 77 of finishing carrier 13 being arranged in one plane to receive in cyclical order the rollers 52 of the transfer mould assembly 19 in the arcuate supporting notches 86 of said mounts 85, and in the slotted guide notches 78 of fixedly supported mounts 77 to serve in alternate order with the mounts 95 of transfer carriers 12 and 14 located in a separate but parallel plane to support the rollers 50 on said transfer mould assemblies 19 in the arcuate support notches 96 of said mounts 95, said notches 86 and notches 96 providing continuous support in sequential order to said transfer mould assemblies 19 as they proceed along an endless travel path back and forth between said finishing carrier 13 and the input carrier 11, and then onward around the circumference of said finishing carrier while supported on the finishing moulds 42 thereof, and guided in the radial movement of the pressing action by the slotted notches 78 of the mounts 77. Also shown in FIG. 8 are the pitch lines of a gear train comprised of gear 30, gear 31, gear 32, gear 33 and gear 34, to form a base line moving in synchronized continuous motion along the travel path of said transfer mould assemblies to coordinate the sequential transfer of said transfer mould assemblies from the notches of one supporting carrier to the notches of the next supporting carrier along said travel path.
FIG. 14 is a diagram similar to the diagram of FIG. 8, to illustrate the relationship of the four transfer carriers of the moulding machine of FIG. 12 wherein the travel path of the transfer mould assemblies 19 is extended in length by means of a twin chain conveyor 215 interposed between transfer carrier 14 and transfer carrier 211 in order to provide sufficient additional space along said travel path for one or more different or additional functions, said conveyor 215 being comprised of two endless conveyor chains 261 travelling in parallel along twin tracks 264 and 265 and continuing around on two sprockets 262 and two sprockets 263, each of said chains being supplied with links 258, said links having notches adapted to receive the rollers 51 of transfer mould assembly 219, as shown in FIG. 17 and FIG. 18, said sprockets 262 being mounted concentrically with gear 231 on the shaft 221 of transfer carrier 211, said sprockets 263 of said conveyor 215 being mounted concentrically with gear 235 on shaft 225, said sprockets 262 and sprockets 263 of said conveyor 215 being synchronized in continuous rotary motion with input carrier 10, transfer carrier 211, transfer carrier 12, finishing carrier 13, and transfer carrier 14 by means of the gear train comprised of their respective gears 30, 231, 32, 34 and 235, the mounts 85 of transfer carrier 211 and the mounts 77 of finishing carrier 13 being arranged in two first planes to receive the rollers 52 of the transfer mould assemblies 219, the mounts 95 of said transfer carriers 12 and 14 beign arranged in a second pair of parallel planes to receive the rollers 50 of said transfer mould assemblies 219, and the travel paths of said chains 261 of said conveyor 215 being arranged in a third pair of parallel planes to receive in cyclical order in the notches of said links 258 the rollers 51 of the transfer mould assemblies 219, the tracks 264 of said conveyor 215 being of sufficient width and located to receive both the chain rollers 259 and the rollers 50 of the transfer mould assemblies 219, said rollers 51 being retained in the notches of said links 258 by the action of said rollers 50 rolling along on said tracks 264 and said transfer mould assemblies 219 being urged along in their travel path by the rollers 51 mounted releaseably in the notches of said links 258 of said continuously moving conveyor chains 261.
FIG. 11 is a diagram illustrating the control system of the moulding machine of FIG. 1 by means of which the travel path and the orientation program of the transfer mould assemblies 19 are precisely determined at all locations. Each of the transfer mould assemblies 19 is mounted with 4 locking pins 48 arranged to cooperate with automatically operated locking devices 49 moveably mounted on the finishing mould carrier 13 whereby to lock each of said transfer mould assemblies 19 in the pressing position as the transfer moulds 41 are mated with the finishing moulds 42 and thereby to maintain said transfer moulds 41 in the pressing position while resisting the radially outward force of the pressing action, and subsequently to unlock said transfer mould assemblies 19 as the transfer moulds 41 begin to be unmated from the finishing moulds 42, each of the transfer mould assemblies 19 being guided in cyclical order into and out of the locking position by the action of said guide rollers 52 travelling along on guide tracks 152a. The total pressure loading exerted upon the preforms between the mated moulds 41 and 42 on the finishing carrier 13 which must be supported by each transfer mould assembly 19 will vary with the total active area of the moulds 41 mounted thereon and the level of pressure per unit of that area required by the finishing process of a particular production line. The selection and design if a locking mechanism as exemplifiedd by the 4 locking pins 481 and the 4 locking arms 491 shown on FIG. 6 and the location and use of the 4 auxiliary load carrying wheels 48 and 49 and their related tracks 148 and 149 as a supplementary or alternative method of supporting the said transfer mould assembly 19 and the moulds 41 mounted thereon in their pressing relationship with their mated moulds 42 as they travel around on the finishing carrier 13 is therefore a matter of conventional design to meet the requirements of said production line and need not be further described here. In their travel about sequentially on the transfer carriers, said transfer mould assemblies are supported releaseably by rollers 50 supported on the notches 96 of the mounts 95 of transfer carrier 14, by rollers 52 supported on the notches 86 of the mounts 85 of the carrier 11, and by rollers 50 supported on the notches 96 of the mounts 95 of the transfer carrier 12, each of said transfer mould assemblies 19 being guided in its travel path by the action of said rollers 50 rolling along on tracks 150a and 150b alternating with said rollers 52 along tracks 152. By means of this mechanism, said transfer mould assemblies 19 and the transfer moulds 41 supported thereon are guided into and out of a regular circular path, in order to follow an optimum path into and out of cooperation with the input moulds 40 on the input carrier and with the finishing moulds on the finishing carrier for interference free entry into deep products as prescribed in said U.S. Pat. No. 3,661,707 issued to Emery and Emery. The precision of control is enhanced by the novel location of said guide tracks 150a, 152 and 150b at greater distances radially outward of the centres of rotation of said transfer carriers 11, 12 and 14, and tangent to said rollers 50 and 52 at the portion of their peripheries most radially distant outward of said centres of rotation, instead of at the inward portion thereof, as described for the transfer mechanism of said U.S. Pat. No. 3,661,707.
The orientation control system of the machine of FIG. 1 is provided with 5 cam followers, circumferentially spaced at intervals of 60 degrees around a sector of 240 degrees, and mounted on lever arms at each end of each of the transfer mould assemblies 19, as illustrated in FIG. 2 and FIG. 3, thereby to provide for a rotation of 180 degrees in cooperation with their respective cam tracks as they travel between the input carrier and the finishing carrier. As shown in FIG. 10, the orientation program begins as the transfer moulds 40 supported on the transfer mould assembly 19 are separated from the finishing moulds 42 supported on the finishing carrier 13 immediately following the finishing oeprations on said finishing carrier, the rollers 48 and 49 being released from tracks 148 and 149 respectively as the guide wheels 50 are directed to guide track 150a, the cam follower 43 enters cam track 143b, and the cam follower 47 is directed against cam track 147b. As the cam follower 43 leaves cam track 143b the cam follower 45 enters cam track 145 b which terminates as cam follower 47 enters a short section of cam track 147c. As cam follower 47 leaves cam track 147c, cam follower 46 enters cam track 146c, which terminates as cam follower 47 enters cam track 147a. As cam follower 47 leaves cam track 147a cam follower 45 enters cam track 145a which terminates as cam follower 46 enters track 146a. The transfer mould assembly 19 and the transfer moulds 41 supported thereon are then directed into cooperation with the finishing moulds 42 supported on the finishing carrier 13, the cam follower 46 having left the track 146, and said transfer mould assembly being oriented into position on the finishing carrier with cma follower 44 travelling in cam track 144a, and cam follower 46 directed against cam track 146b.
This invention is not limited in its application to the configuration described herein for the moulding or finishing machines of FIG. 1, FIG. 12 or FIG. 20 because the concept of releaseably mounted and freely transferable transfer mould assemblies provides the opportunity of extending the length and changing the configuration of said travel path by including therealong additional transfer carrier wheels or chain conveyors, or by changing the length or configuration or arrangement in sequence thereof, and by the addition of an alternating series of transfer carriers in order to present any face of the product at any point in its travel path to facilities for printing, labelling, laminating, post forming or post drying in a continuous production line and in continuous motion through as may be required to produce the desired final product. | In a precision moulding or finishing machine operating in continuous motion to form fully finished products from materials such as wood pulp, an improved system for transferring a preform into a transfer mould and thence into precision mating with a finishing mould in a pressing operation suitable for manufacturing products such as bowls, cups, pots and boxes, the preform remaining in one pair of moulds throughout the pressing operation. Transfer mould assemblies are transferred sequentially from one transporting carrier to another for fully rotatable mounting on releasable mounts guided precisely through a preferred endless travel path and orientation program. The concept of a releasably mounted and freely transferable transfer mould assembly provides for the addition of such functions as printing and labelling in the same continous production line. | 3 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an X-ray anode which comprises a coating which generates X-rays on bombardment with focused electrons and is joined to a support body. The support body comprises a strength-imparting region composed of a material having a strength at 500° C. of greater than 100 MPa.
In the generation of X-rays by bombardment of an anode material with a focused electron beam, about 99% of the radiant energy is converted into heat. The focal spot is therefore subjected to very high specific inputs of energy per unit area which are in the order of magnitude of from 10 to 100 MW/m 2 . This results in very high focal spot temperatures and in the case of pulsed electron bombardment of rotating X-ray anodes thermomechanical fatigue of the focal track. The limit of possible energy input is given by aging of the focal track combined with a progressive decrease in the dose performance and/or with the loss of the high-voltage stability of the tubes. To slow these effects, optimized removal of heat from the focal spot or the focal track is necessary.
The largest part by far of the radiation sources used in X-ray computer tomography are rotating X-ray anodes in which the energy of the electron beam brought into line focus is distributed around a ring, known as the focal track, by rotation of the anode at high speed. The energy introduced during recording of the image of up to some megajoules is firstly mostly temporarily stored in the X-ray anode and, in particular, given off to the surrounding cooling medium during the pause between recording of images by radiation, in the case of rotational anodes having a sliding groove bearing also by heat conduction into the bearing.
Rotating anodes according to the prior art comprise a coating which generates X-rays on bombardment with focused electrons, for example a coating composed of a tungsten-rhenium alloy, which is applied to a support body, for example a disk composed of a molybdenum-based material. A molybdenum-based material customary for this application is TZM having the composition Mo-0.5% by weight of Ti-0.08% by weight of Zr-0.04% by weight of C. Depending on the field in which the anode is used, a graphite body can be soldered onto the rear side of the metal disk in order to increase the heat storage capacity and radiation of heat. At the initial temperature for operation of the tube (about 40° C.), the thermal conductivities of W-10% by weight of Re, TZM and graphite are about 85, 125 and 135 W/m·K, respectively, but decrease significantly with increasing anode temperature.
In a new generation of X-ray tubes, known as rotary tubes, the anode is fixed as base to a tube which rotates as a whole and the anode is actively cooled on the rear side. The energy balance of the anode is dominated by the removal of heat into the cooling medium. Heat storage plays a minor role. DE 10 2005 039 188 B4 describes an X-ray tube having a cathode and an anode made of a first material, with the anode being provided on its first side facing away from the cathode with, at least in sections, a heat conducting element made of a second material which has a higher thermal conductivity than the first material in order to conduct away heat, where the second material has a thermal conductivity of at least 500 W/mK and the second material is made of titanium-doped graphite.
DE 10 2004 003 370 A1 describes a high-performance anode base for a directly cooled rotary tube, which base comprises a high-temperature-resistant material such as tungsten, molybdenum or a composite of the two materials, with the underside of the anode base in the region of the focal point track being shaped and/or another highly thermally conductive material being introduced or applied in this region in such a way that improved heat removal and thus a lower temperature gradient within this region of the material is obtained. Copper is mentioned as material having a high thermal conductivity.
There have been numerous approaches to improving the heat removal in rotating X-ray anodes in past years. Despite the excellent thermal conductivity of diamond at room temperature, diamond received little attention because of the sharply decreasing thermal conductivity at elevated temperatures and the conversion into graphite at T>1100° C. Thus, U.S. Pat. No. 4,972,449 proposed the use of a diamond layer intercalated between the coating and the support body. However, diamond also has a significantly lower coefficient of expansion than the adjacent materials, as a result of which stresses are induced in the composite body. Furthermore, the classical powder-metallurgical production route for X-ray anodes, namely the powder-metallurgical joining of focal track coating and support body, cannot be employed since the sintering process would lead to conversion of the diamond layer into graphite. X-ray anodes according to U.S. Pat. No. 4,972,449 can therefore only be produced by coating methods, for example CVD processes.
BRIEF SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an X-ray anode which has a support body having improved heat removal. A further object is to reduce the stresses in the composite of support body/coating.
The X-ray anode comprises a coating and a support body, with the support body comprising a strength-imparting region and also a region composed of a diamond-metal composite. The diamond-metal composite comprises diamond grains surrounded by binder phase(s). The binder phase(s) comprises/comprise a binder metal, preferably a binder metal based on copper, silver, aluminum and alloys of these materials, and also optionally up to 20% by volume of carbides. Varying the diamond content and binder phase content makes it possible to match the diamond-metal composite to the surrounding materials in terms of thermal conductivity and thermal expansion in such a way that tailored solutions for a wide variety of requirements are possible. A gradated structure of the diamond-metal composite in which the proportion of diamond is highest near the coating and decreases in the direction of the maximum heat flow can be advantageous. In this way, it is possible to achieve minimization of the stresses in the composite caused by different coefficients of thermal expansion of the materials used. Furthermore, diamond powder can be processed with a broad particle size spectrum. Preferred particle sizes are in the range from 50 to 400 μm, ideally from 100 to 250 μm. Apart from natural diamonds, it is also possible to process cheaper synthetic diamonds in this way. The preferred proportion by volume of the diamond grains is from 40 to 90% by volume, and that of the binder phase(s) is from 10 to 60% by volume. A diamond content of from 40 to 90% by volume ensures that the stresses in the composite are reliably reduced to a level which is not critical for use. Particularly advantageous diamond contents and binder phase contents are from 50 to 70% by volume and from 30 to 50% by volume, respectively.
The binder metal preferably comprises from 80 to 100 atom % of at least one matrix metal from the group consisting of Cu, Ag, Al, from 0 to 20 atom % of a metal having a solubility at room temperature in the matrix metal of less than 1 atom % and from 0 to 1 atom % of a metal having a solubility at room temperature in the matrix metal of greater than 1 atom %, balance production-related impurities. Alloying elements having a solubility at room temperature in the matrix metal of less than 1 atom % reduce the thermal conductivity to a small extent and can therefore be present in amounts of up to 20 atom %, while alloying elements having a solubility of greater than 1 atom % are restricted to 1 atom % because of their adverse effect on the thermal conductivity.
Good bonding between the diamond phase and metal phase is necessary in order to ensure a transition from the phonon conductivity of diamond to the electron conductivity of the binder metal. This can be achieved, for example, by formation of a carbidic phase located between the diamond phase and the metal phase. Studies have shown that even carbide films having a thickness of a few layers of atoms significantly improve the thermal conductivity. Carbide-forming elements which have been found to be useful are the metallic elements of groups 4b (Ti, Zr, Hf), 5b (V, Nb, Ta), 6b (Cr, Mo, W) of the Periodic Table and also B and Si. The weak carbide formers Si and B are particularly suitable. When the matrix metal is a carbide-forming element such as aluminum, the addition of further carbide-forming elements can be omitted. Furthermore, it is advantageous for the element forming the carbidic phase also to be present in the binder metal. Preference is given to the carbide-forming elements which have a solubility in the respective matrix metal of less than 1 atom %. If the solubility is greater, the thermal conductivity of the binder metal and thus that of the diamond-metal composite are again reduced. Preferred compositions of the binder metal are aluminum materials comprising from 0.005 to 3 atom % of one or more of the elements V, Nb, Ta, Ti, Zr, Hf, B, Cr, Mo, W and/or comprising from 0.005 to 20 atom % of Si.
On the basis of Ag, these are materials comprising from 0.005 to 5 atom % of one or more elements of the group Zr, Hf and/or from 0.005 to 10 atom % of one or more elements of the group V, Nb, Ta, Cr, Mo, W and/or from 0.005 to 20 atom % of Si. Particularly advantageous properties are achieved using Cu-based matrix metals which are alloyed with from 0.005 to 3 atom % of one or more elements of the group Ti, Zr, Hf and/or from 0.005 to 10 atom % of one or more elements of the group Mo, W, B, V, Nb, Ta, Cr, and/or from 0.005 to 20 atom % of B. Ag alloys with from 0.1 to 12 atom % of Si and Cu alloys with from 0.1 to 14 atom % of boron, balance usually impurities have been found to be particularly advantageous binder metals.
A particularly advantageous effect can also be achieved when coated diamond powders (metallic or carbidic layer) are used.
The use of the diamond-metal composite according to the invention makes it possible to conically widen the heat flow and thus increase the efficiency of active cooling in the case of actively cooled X-ray anodes. Comprehensive experiments on such X-ray anodes have shown that the solution according to the invention reduces the temperature to such an extent that the predicted low thermal conductivity of the diamond-metal composite at elevated use temperatures still does not have a function-limiting effect.
Since the diamond-metal composites according to the invention have limited mechanical properties such as tensile and compressive strength, fracture toughness and fatigue strength and can accordingly not be thermally cycled as free-standing structure under use conditions of X-ray anodes, the support body comprises not only the diamond-metal composite but also a strength-imparting region of a structural material which has a strength at 500° C. of greater than 100 MPa. The diamond-metal composite is protected against interfering deformation or initiation of cracks caused by centrifugal forces or thermomechanical stresses by the structural stiffness of the structural component. This makes it possible to optimize the diamond-metal composite firstly in respect of thermal conductivity, in particular by increasing the proportion of diamond. Secondly, the diamond-metal composite can be matched in terms of its thermal expansion to the structural material. In this way, the functions of the support body can be decoupled from firstly structural strength and rupture strength and secondly heat removal. Particularly suitable structural materials which may be mentioned are Mo, Mo alloys, W, W alloys, W—Cu composites, Mo—Cu composites, particle-reinforced Cu alloys and particle-reinforced Al alloys. As particularly advantageous molybdenum alloys, mention may be made of TZM (Mo-0.5% by weight of titanium-0.08% by weight of zirconium-0.04% by weight of C) and MHC (Mo-1.2% by weight of Hf-0.08% by weight of C).
The region of the diamond-metal composite can directly adjoin the coating. This is possible and appropriate when the temperature on the rear side of the coating can be reduced by the diamond-metal composite to such an extent that no damage to the material, for example melting of the binder phase(s) of the diamond-metal composite, occurs. If this is not the case, it is advantageous for the strength-imparting region composed of a structural material which is stable under use conditions, preferably molybdenum, tungsten or an alloy of these metals, to extend between the diamond-metal composite and the coating.
The diamond-metal composite is preferably arranged under that region of the coating in which heat arises due to the action of the electron beam. In the case of a rotating X-ray anode, this is the ring-shaped focal track. This gives preferred embodiments for the region of the diamond-metal composite, namely regions having an axially symmetrical geometry, for example a disk or a ring. The cross section is preferably approximately rectangular or trapezoidal.
Viewed in the direction of the maximum heat flow, it is also advantageous for the region of the diamond-metal composite to be followed by a further heat-removing region composed of a highly thermally conductive metal which can be given its final shape, in particular in respect of the construction of cooling structures, by means of conventional cutting machining processes. As highly thermally conductive metals, mention may be made of copper, aluminum, silver and alloys thereof. This heat-removing region is also preferably configured as a ring-shaped element or as a disk and firmly bonded to the diamond-metal composite and/or the strength-imparting region.
In the direction of maximum heat flow, the X-ray anode preferably has the following structure at least in the region of the maximum heat stress:
from 0.01 mm to 1 mm coating, from 0 to 4 mm strength-imparting region, from 2 to 15 mm region of the diamond-metal composite and from 0 to 10 mm heat-removing region. A minimum thickness of the coating of 0.01 mm can is necessary for X-ray-physical reasons. At coating thicknesses above 1 mm and/or a thickness of the strength-imparting region above 4 mm, the heat removal is reduced since the W—Re alloys which are customarily used and the structural materials available have a reduced thermal conductivity compared to the diamond-metal composite. It is particularly advantageous for the thickness of the coating to be from 0.2 to 0.4 mm and that of the strength-imparting region to be from 0.5 to 4 mm.
The inventive structure of an X-ray anode can be employed particularly advantageously, in particular, in the case of rotating anodes and when the rotating anode is in turn used as actively cooled bottom of a rotary tube. To achieve sufficient structural strength of the rotating anode, it is found to be useful for the center to be formed by only the structural material. Furthermore, it is advantageous for the region of the diamond-metal composite to be embedded as ring- or disk-shaped element in an appropriate depression of the strength-imparting region of the support body and thus be supported by the latter against mechanical stresses which occur. The structural material is advantageously firmly bonded on one side to the coating and on the other side to the diamond-metal composite. The firmly bonding of the structural component and the diamond-metal composite can advantageously be carried out in situ during the synthesis in suitable recesses in the strength-imparting region of the anode body (for example by pressure infiltration or by hot isostatic pressing). On the other hand, it is possible to synthesize the composite on its own and produce a body of suitable shape therefrom and then firmly bond this body to the structural component, for example by soldering or another known joining process.
To produce the diamond-metal composite, there are a number of available processes in which the binder metal is firmly bonded to the diamond either via the melt phase or via the solid phase. Via the melt phase, the processes advantageously proceed by means of pressure infiltration. Typical infiltration temperatures are about 100° C. above the respective melting point of the binder metal. Reactions with the diamond grain then may form the abovementioned carbide phases enveloping the diamond grains.
A particularly suitable production process comprises the following production steps:
production of a composite body made up of the structural material and the coating material by powder-metallurgical composite pressing/sintering/forging or application of the coating material to the structural material by vacuum plasma spraying; introduction of a depression into the structural material on the side facing away from the coating; introduction of diamond powder having a particle size of from 50 to 400 μm into the depression, with the diamond powder being able to be uncoated or coated (layer thickness from 0.05 to 50 μm) preferably with a metal or a carbide of a metal of groups 4b, 5b, 6b of the Periodic Table, B and Si; infiltration of the diamond powder bed with the binder metal at a pressure of from 1 to 500 bar and a temperature T such that the liquidus temperature of the binder metal<T<liquidus temperature of the binder metal plus 200° C.; optionally with an excess of the binder metal, to form the heat-removing region; machining.
In the production of the bond between diamond grain and binder metal in the solid phase, the bond between the diamond grain and the binder metal is formed by diffusion. The required diffusion paths can be achieved even at temperatures T of ˜0.5-0.8 T m (T m =melting point of the binder metal in degrees kelvin) and hold times of a few hours. Suitable processes are, for example, hot pressing and hot isostatic pressing of diamond/metal powder mixtures. Bonding is advantageously improved or accelerated by means of suitable coatings on the diamond grains. In the case of the solid-phase reaction, it is possible, with appropriate pretreatment of the diamond grains and selection of the consolidation conditions, to reduce the contents of additive materials by orders of magnitude or possibly dispense with these entirely, as a result of which the high thermal conductivity of the pure binder phase can largely be retained.
Combinations of the two reaction routes, for example brief passing through the melt phase under super-atmospheric pressure for pore-free backfilling of the diamond bed followed by a solid-state pressure diffusion phase at decreased temperatures, can also be advantageous, in particular for achieving high proportions of diamond in the composite.
A particularly suitable process comprises the production steps:
production of a composite body made up of the structural material and the coating material by powder-metallurgical composite pressing/sintering/forging or application of the coating material to the structural material by vacuum plasma spraying; introduction of a depression into the structural material on the side facing away from the coating; introduction of a mixture of diamond powder and the binder metal into the depression, with the diamond powder having a particle size of from 50 to 400 μm and being able to be uncoated or coated (layer thickness from 0.05 to 50 μm) preferably with a metal or a carbide of a metal of groups 4b, 5b, 6b of the Periodic Table, B and Si; hot pressing of the mixture at a pressure of from 10 to 200 MPa and a temperature T such that 0.6× solidus temperature of the binder metal<T<solidus temperature of the binder metal; optionally with an excess of the binder metal, to form the heat-removing region; machining.
A further suitable process comprises the production steps:
production of a composite body made up of the structural material and the coating material by powder-metallurgical composite pressing/sintering/forging or application of the coating material to the structural material by vacuum plasma spraying; introduction of a depression into the structural material on the side facing away from the coating; production of a green body by pressing of a mixture of diamond powder and binder metal powder, with the diamond powder having a particle size of from 50 to 400 μm and the binder metal powder having a particle size of from 0.5 to 600 μm and the diamond powder being able to be uncoated or coated (layer thickness from 0.05 to 50 μm) preferably with a metal or a carbide of a metal of groups 4b, 5b, 6b of the Periodic Table, B and Si, at a pressure of preferably from 70 to 700 MPa; introduction of the green body into the depression of the structural material and canning of the assembly produced in this way using customary canning materials (for example steel, titanium); hot isostatic pressing of the canned assembly at a pressure of from 50 to 300 MPa and a temperature T such that 0.6× solidus temperature of the binder metal<T<liquidus temperature of the binder metal plus 200° C.; optionally with an excess of the binder metal, to form the heat-removing region machining.
Further processes, in particular processes for producing composites, e.g. gas-phase infiltration of the binder metal, are in principle also possible for producing the diamond-metal composite.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention is illustrated below by means of examples.
FIG. 1 schematically shows the cross section of the X-ray anode according to the invention as per example 4
FIG. 2 schematically shows the cross section of the X-ray anode according to the invention as per example 5
FIG. 3 schematically shows the cross section of the X-ray anodes according to the invention as per examples 6 and 7
DESCRIPTION OF THE INVENTION
Example 1
To produce the binder phase based on Cu, disks of the high-strength Mo alloy TZM (Mo-0.5% by weight of Ti-0.08% by weight of Zr-0.01 to 0.06% by weight of C) having a diameter of 50 mm and a thickness of 30 mm were produced by a conventional powder-metallurgical route via powder pressing/sintering/forging. A cylindrical depression having a diameter of 30 mm and a depth of 20 mm was machined into these disks. In the following working step, a diamond bed having an average particle diameter (determined by laser light scattering) of 150 μm was introduced in each case into the depression formed in this way and the ring-shaped depression was infiltrated with Cu alloys having the following compositions: Cu-0.5 atom % of B, Cu-2 atom % of B and Cu-8 atom % of B by gas pressure infiltration to produce the diamond-metal composite.
In addition, Nb-coated (layer thickness about 1 μm) diamond powder having an average particle diameter (determined by laser light scattering) of 150 μm was introduced into the ring-shaped depression and pure Cu in particulate form was positioned above it. Identical experiments were carried out using Cr-, Ti- and Mo-coated powders. The gas pressure infiltration was in each case carried out under an Ar protective gas atmosphere at 1100° C. and a gas pressure of 2 bar. The proportion by volume of diamond was about 55% in all specimens. The thermal conductivity of the Cu-diamond composites at 500° C. was in the range from 290 to 350 W/m·K.
Example 2
To produce the binder phase based on Ag, disks as described in example 1 were produced. To produce the diamond-metal composite, a diamond bed having an average particle diameter (determined by laser light scattering) of 150 μm was in each case introduced into the depression and the ring-shaped depression was infiltrated with Ag alloys of the following compositions: Ag-0.5 atom % of Si, Ag-3 atom % of Si, Ag-11 atom % of Si and Ag-18 atom % of Si by gas pressure infiltration.
In addition, Nb-coated (layer thickness about 1 μm) diamond powder having an average particle diameter (determined by laser light scattering) of 150 μm was introduced into the ring-shaped depression and pure Ag in particulate form was positioned above it. Identical experiments were carried out using Cr-, Ti- and Mo-coated powders. The gas pressure infiltration was in each case carried out under an Ar protective gas atmosphere at 1000° C. and a gas pressure of 2 bar. The proportion by volume of diamond was about 55% in all specimens. The thermal conductivity of the Ag-diamond composites at 500° C. was in the range from 340 to 440 W/m·K.
Example 3
To produce the binder phase based on Al, disks as described in example 1 were produced. To produce the diamond-metal composite, a diamond bed having an average particle diameter (determined by laser light scattering) of 150 μm was in each case introduced into the depression and the ring-shaped depression was infiltrated with Al materials of the following compositions: Al, Al-3 atom % of Si, Al-12 atom % of Si and Al-15 atom % of Si by gas pressure infiltration.
In addition, Nb-coated (layer thickness about 1 μm) diamond powder having an average particle diameter (determined by laser light scattering) of 150 μm was introduced into the ring-shaped depression and pure Al in particulate form was positioned above it. Identical experiments were carried out using Cr-, Ti- and Mo-coated powders. The gas pressure infiltration was in each case carried out under an Ar protective gas atmosphere at 700° C. and a gas pressure of 2 bar. The proportion by volume of diamond was about 55% in all specimens. The thermal conductivity of the Al-diamond composites at RT was in the range from 400 to 450 W/m·K.
Example 4
A rotating anode - 1 - having a structure as shown in FIG. 1 was produced as follows: the strength-imparting region - 4 - of the support body - 3 - was produced from TZM by a conventional powder-metallurgical route by means of powder pressing/sintering/forging and turning of the front contour (having an external diameter of 125 mm). The X-ray producing coating - 2 - composed of W-5% by weight of Re was then applied by means of vacuum plasma spraying. A ring-shaped region having a width of 25 mm was turned out of the strength-imparting region - 4 - of the support body - 3 - below the coating - 2 - to leave a residual thickness of the strength-imparting region - 4 - of 1 mm. In the following working step, a diamond bed having an average particle diameter (determined by laser light scattering) of 150 μm was introduced into the resulting ring-shaped groove to produce the region - 5 - of the diamond-metal composite and the ring-shaped depression was infiltrated with a Cu-4 atom % of B alloy which was positioned in particulate form on the diamond powder bed by gas pressure infiltration. The gas pressure infiltration was carried out under an Ar protective gas atmosphere at 1100° C. using a gas pressure of 2 bar. Utilizing a suitable graphite tool, the heat-removing region - 6 - in the form of a Cu-4 atom % of B backing plate having a thickness of 3.7 mm was cast behind the diamond composite simultaneously with the infiltration. To improve heat transfer to the cooling medium, a fin structure was machined into this backing plate. The resulting region - 5 - composed of the diamond-metal composite had a proportion by volume of about 55% of diamond and a coefficient of expansion at RT of 6.5 E −6 /° K. The thermal conductivity of the Cu-diamond composite was 480 W/m·K at 22° C. and 350 W/m·K at 500° C.
Example 5
A rotating anode - 1 - having a structure as shown in FIG. 2 was made as follows. The strength-imparting region - 4 - of the support body - 3 - was produced from the high-strength Mo alloy MHC (Mo-1.2% by weight of Hf-0.04-0.15% by weight of C), with the X-ray-producing coating - 2 - composed of W-10% by weight of Re being joined to the strength-imparting region - 4 - by the customary powder-metallurgical method by means of copressing/sintering and bonding forging. The ring-shaped groove was produced as described in example 4. In the following working step, a diamond bed having an average particle diameter of 150 (determined by laser light scattering) was introduced into the machined ring-shaped groove to produce the region - 5 - composed of the diamond-metal composite. An Ag-11 atom % of Si alloy in particulate form was positioned on the diamond bed. The infiltration was carried out under an Ar protective gas atmosphere at 1000° C. using a gas pressure of 2 bar. The region - 5 - was concluded on the underside of the rotating anode - 1 - with an excess of metal melt having a thickness of about 2 mm. The use of the Ag matrix enabled a thermal conductivity of 590 W/m·K at 22° C. and 420 W/m·K at 500° C. to be achieved.
Example 6
A rotating anode - 1 - having a structure as shown in FIG. 3 was produced as follows. The production of the strength-imparting region - 4 - composed of TZM (thickness 15 mm, diameter 140 mm) and application of the coating - 2 - composed of W-5% by weight of Re were carried out in a manner analogous to example 4. A groove was turned in the strength-imparting region - 4 - of the support body - 3 - in the ring-shaped region (external diameter 125 mm, internal diameter 80 mm) to be backfilled with diamond-metal composite to leave a residual thickness of the TZM of 1 mm. The strength-imparting region - 4 - together with a ring-shaped coating disk built up thereon formed part of the hot-pressing tool which was backfilled with a mixture of 50% by volume of diamond and 50% by volume of high-purity copper to form the region - 5 -. The diamond grains had a diameter of 150 μm (determined by laser light scattering) and were coated with 1 μm of SiC for later bonding of the matrix. The high-purity Cu powder likewise had a particle diameter of 150 μm. Finally, a covering bed of 3 mm copper powder having the same particle size was applied to form the heat-removing region - 6 -. This bed was prepressed at room temperature and hot pressed at a temperature of 900° C. for 1.5 hours at a pressure of 40 MPa and in this way densified to 99.8% of the theoretical density. At the same time, a strong and readily thermally conductive bond between the diamond grains and the copper matrix and between the matrix and the support body - 3 - was formed by diffusion between SiC and Cu.
The thermal conductivity measured on the resulting copper-diamond composite was 490 W/m·K (at 22° C.)
Example 7
A rotating anode - 1 - having a structure as shown in FIG. 3 was produced as follows. The production of the strength-imparting region - 4 -, application of the coating - 2 - and production of the ring-shaped region were carried out as described in example 5. A powder bed composed of a mixture of 70% by volume of diamond and 30% by volume of silver to form the region - 5 - was densified by means of die pressing to give a pressed body in the approximate shape of the turned-out ring-shaped region of the strength-imparting region - 4 - and placed in the turned-out ring-shaped region. The diamond grains had a diameter of 300 μm and were coated with 3-5 μm of SiC. The Ag powder had a particle diameter of 150 μm. An Ag foil having a diameter of 140 mm and a thickness of 3 mm was laid onto the rear side of the diamond-Ag green body. The total structure was welded in a vacuum-tight manner into a steel can and the latter was evacuated. The Ag present was melted in the HIP process by melting at 980° C. with a hold time of 2 minutes and a pressure of 50 MPa, and the hollow spaces of the green body were thus backfilled with Ag melt. The temperature was subsequently reduced to 650° C. and the canned component was maintained under a pressure of 70 MPa for 1 hour. Cooling to room temperature was likewise carried out under super-atmospheric pressure in the range of about 70 MPa, with a hold time at 400° C. of 2 hours. The silver-diamond composite obtained in this way had a thermal conductivity of 610 W/m·K.
As reference anode for comparative tests in X-ray tubes, use was made of an anode for rotary tubes which had the same structure and was made according to the present-day state of the art but was backfilled with copper instead of diamond-metal composite.
All rotating anodes backfilled with diamond-metal composite as described in examples 4 to 7 displayed excellent use behavior when tested in rotary tubes under test conditions more severe compared to the present-day limiting load (increase in the electric power by 20% compared to the reference anodes according to the prior art) and showed a significantly slowed decrease in the X-ray dose over the test time compared to the reference anodes despite the increased load. The reduction in the roughening of the focal track, which is responsible for the decrease in the X-ray dose over the life of the anode, correlated in a good approximation with the relative increase in the thermal conductivity of the diamond-metal composite present in each case. In destructive analyses of the various anodes carried out after the end of the test, no damage to the bond between the strength-imparting component and the diamond-metal composite or within the latter between diamond grains and binder metal was observed. | An X-ray anode includes a coating and a support body. In addition to a strength-imparting region, the support body has a region formed of a diamond-metal composite material. The diamond-metal composite material is formed of 40 to 90% by volume diamond particles, 10 to 60% by volume binding phase(s) formed of a metal or an alloy of the metals of the group consisting of Cu, Ag, Al and at least one carbide of the elements of the group consisting of Tr, Zr, Hf, V, Nb, Ta, Cr, Mo, W, B, and Si. The highly heat-conductive region can be form-lockingly connected at the back to a heat-dissipating region, for example formed of Cu or a Cu alloy. The X-ray anode has improved heat dissipation and lower composite stress. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 62/000,478 filed May 19, 2014, and incorporated herein by reference in its entirety.
FIELD OF DISCLOSURE
The present disclosure generally relates to forensic data recovery and more particularly to accessing hidden data files.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Existing methods to recover hidden data files from computational storage devices are tedious and time-consuming. Solid state drives (SSDs or SSD when discussing a singular solid state drive) are complex computational storage devices that use NAND flash memory chips. Such memory devices have a high data storage capacity; however, they are difficult to manage because existing data in a chip cannot simply be overwritten, but rather must first be erased, and then written on again. Furthermore, data must be erased in large blocks; specifically, on the order of a million bytes, but may also be written in smaller blocks, on an order of thousands of bytes. These hindrances pose a problem for forensic analysts and others seeking to recover hidden data because they impose significant time constraints on the process and thus potentially prevent successful hidden data recovery from ever being accomplished.
In an effort to make the above memory chips easier to use and data more accessible, a flash translation layer (FTL) of software is included in the SSD to handle the details of deleting old data and writing new data, thus taking the burden of this task away from the host operating system. A memory array of the SSD has two spaces: a logical block address (LBA) space and a physical block address (PBA) space. These spaces are overlaid spaces. The LBA space is the data structure that the host computer sees and comprises the sectors in which data is stored. The PBA space is the memory provided by flash chips, and is generally up to 20% larger than the LBA space, depending on the particular configuration. The LBA space is mapped into the PBA space by the FTL software.
A legacy hard disk drive (HDD), a similar device, has a simpler configuration in that its LBA and PBA spaces essentially have a corresponding size ratio of one-to-one, with the PBA being only a fraction of a percent larger than the LBA.
The extra PBA space in the SSD is referred to as over provisioning space and has several purposes. These purposes include storing SSD firmware (which is the firmware that runs the SSD's internal microcontroller and which is typically 100K to 200K bytes, though this range is not provided to be limiting), NAND flash wear leveling, bad block management, housing FTL management tables, and garbage collection.
Wear leveling is a type of software algorithm that distributes the reading and writing activities evenly among the flash chips on the SSD. This is needed because NAND flash exhibits rapid wear out mechanisms, resulting in degradation of the data written to the SSD. FTL management tables comprise memory storage for the LBA/PBA mapping table, which can be gigabytes in size. They also include other general task, or housekeeping, information. Garbage collection is a software algorithm which collects and erases currently unused but previously written areas in flash memory in order to prepare clean sections for future writes and avoid delays in erasing. All of the above functions are well known.
A problem occurs as a side effect in the operation of the SSD, which is that forensically valuable data gets moved out of the LBA space to where it cannot be accessed via the host computer interface. The management complexity and non-one-to-one LBA and PBA memory spaces of the SSD (as contrasted from the legacy HDD) further impede successful data recovery and force individuals who want to recover the data, such as forensic analysts, to attempt to reverse engineer the algorithms in the SSD to obtain the hidden data, which can be very time consuming.
Referring now to FIG. 1 , a block diagram showing an exemplary relationship between the PBA space and the LBA space in the memory array of an SSD space is shown. Importantly, the PBA space 100 is usually larger than the LBA space 101 (typically by seven percent (7%), but in some instances up to twenty percent (20%)) within the memory array 10 of the SSD. For example, an SSD with a 128 GB storage capacity would have about 119 GB of LBA space available for file storage. The remaining 9 GB would be used as over provisioning space and may be a resource for wear leveling, garbage collection, and other SSD firmware functions. The LBA space 101 is a logical representation, and does not reveal where in the memory devices data is stored. The PBA space 100 consists of memory in the form of physical flash memory chips. As shown, the LBA space 101 is a subset of the PBA space 100 .
The data that is stored on SSDs and HDDs is in aggregations known as sectors. A sector is typically 512 bytes in length, but may be larger. The NAND flash chips can accommodate this form of data storage, considered sectors, and so, in most cases, integral numbers of LBA sectors are stored in physical flash memory pages.
There are currently two main methods to read the over provisioning space as a first step to recover hidden data. The first method consists of using custom read commands over the host interface port of the SSD. However, these commands are not standardized and are proprietary, and do not even exist for most SSD models, or are password protected or encrypted. These characteristics make it hard for individuals to access the hidden data.
The second method of reading the over provisioning space consists of reading the flash chips directly. This can be done by removing the flash chips and inserting them into a reading device that reads and stores their contents. To remove the flash chips involves desoldering the flash chips form the memory array. This may also be accomplished via electronic means of reading the flash chips while they remain installed on the SSD circuit.
There are several remaining steps currently required to recover hidden data from an SSD. After the flash memory chips are read and the data is saved as a PBA image, the LBA space is read over the host computer interface and the data is saved as a LBA image. Next, the flash memory errors in the PBA image are corrected, if possible. The error correction information is deleted from the image, leaving only data. The PBA and LBA images are then compared, noting which sectors match in each image. Finally, the unmatched PBA sectors are separated and stored as hidden data.
The described existing process contains several issues. First, the format of the data within a flash memory chip varies greatly depending on the make and model of the SSD, as well as the make and model of the memory chip. This format must be determined before any hidden data can be recovered, which takes time. Additionally, the error correction code (ECC) that is used to prevent flash memory bit errors is typically unknown and is not published by the SSD manufacturer. It therefore may not be possible to correct errors in the raw data that is read from the flash chips. Further complicating matters is that the amount of data may be huge, reaching as high as the terabyte range. This means that the algorithms that are used must be of low complexity and have a low run time for large data sets, which could take days, weeks, or longer to complete. The standard approach to this problem is to represent each sector with a short hash value. For example, the use of an eight-byte hash value for each sector would reduce the data storage requirements by 98.5% compared to handling the raw 512-byte sectors. Provisions would need to be made to handle hash collisions.
However, even with the above hash optimization, the LBA and PBA images still bear no relation to one another due to the wear leveling algorithm used in the SSD, which significantly fragments stored files. This means that an LBA image file that is stored in contiguous sectors will be distributed over a large area of the PBA image with no simple mapping relationship, that mapping relationship being different for every make and model of SSD, as well as changing as a given SSD is used. This means that the matching process could potentially be an order of n 2 process, which would be quite slow.
The above process works well when the errors in the PBA image have been corrected. If they have not been corrected, then any bit errors in the PBA sector source data will skew hash values and prevent them from matching to corresponding LBA sectors.
Given the foregoing, what is needed are methods which facilitate identifying and recovering data that is normally hidden in NAND flash memory arrays in SSDs and is normally inaccessible using host computer interfaces, without having to reverse engineer the algorithms in the SSD, using a hash value that is tolerant of some small percentage of bit errors in the source data.
SUMMARY
This Summary is provided to introduce a selection of concepts. These concepts are further described below in the Detailed Description section. This Summary is not intended to identify key features or essential features of this disclosure's subject matter, nor is this Summary intended as an aid in determining the scope of the disclosed subject matter.
A method of isolating hidden data in a solid state memory system is disclosed. The method comprises obtaining a logical block address (LBA) image from the memory system, obtaining a physical block address (PBA) image, and determining whether an error exists in the PBA image and correcting the error. The method also comprises calculating an error tolerant cyclic redundancy check (ETCRC) on each sector of the LBA image and building a search tree indexed on the ETCRC value. For each sector in the PBA image, the method also comprises computing the (ETCRC) value and searching for the ETCRC value in the LBA search tree. If the ETCRC value found, the method compares the cyclic redundancy check (CRC) of the LBA and PBA sectors. The method also provides for outputting to an output file the PBA sector as hidden data if either the ETCRC value is not found in the LBA search tree or the CRC comparison fails.
Another method of computing a total hash function of an array of values, which limits the impact of a change in the array of values to one subfield in the hash value is also disclosed. The method comprises dividing the array of values into a number of sections, computing a hash function over each section, and concatenating the computed hash function values to create a total hash function of the array of values, wherein a change in one of the array of values is reflected as a change in the total hash function in only one subfield.
A hidden data determination system for locating hidden date in a memory array of a solid state device is also disclosed. The system comprises an interface to access memory space on a memory device and a graphics processing unit to create a plurality of hash values for a logical block address (LBA) memory space of the memory device and to create a plurality of hash values for a physical block address (PBA) memory space of the memory to identify data hidden within the PBA memory space from view of the LBA memory space. The system also includes display device to show the data hidden.
BRIEF DESCRIPTION OF THE DRAWINGS
A more particular description briefly stated above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments and are not therefore to be considered to be limiting of its scope, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is an image illustrating an exemplary relationship between the PBA space and the LBA space in the memory array of an SSD;
FIG. 2 shows a block diagram of LBA data used to construct an Adelson-Velsky and Landis' (AVL) tree;
FIG. 3 shows an embodiment of a completed AVL tree, and each of several unique nodes is shown with a unique linked list;
FIG. 4 shows a block diagram of PBA data used in conjunction with the LBA AVL tree;
FIG. 5 shows a block diagram of ETCRC bytes relationship to byte (subfield) relationship to subsets of a sector;
FIG. 6 shows a representation of a PBA and an LBA ETCRC during a puncturing process;
FIG. 7 shows a flowchart of an embodiment of a method;
FIG. 8 shows a continuation of the flowchart of the embodiment of the method started in FIG. 7 ;
FIG. 9 shows an embodiment of the subroutine of BUILD LBA AVL TREE shown in FIG. 7 ;
FIG. 10 shows an embodiment of the subroutine COPY LBA AVL TREE AND PUNCTURE shown in FIG. 7 ;
FIG. 11 shows an embodiment of the subroutine PROCESS INPUTFILE SECTORS shown in FIG. 8 ;
FIG. 12 shows an embodiment of a table of puncturing patterns;
FIG. 13 shows an embodiment of a block diagram of an AVL tree labeled with sample ETCRC values;
FIG. 14 shows an embodiment of a block diagram of information in the AVL tree after puncturing and rebalancing of the AVL tree; and
FIG. 15 shows a block diagram of an embodiment of a device as disclosed herein.
DETAILED DESCRIPTION
Embodiments are described herein with reference to the attached figures wherein like reference numerals are used throughout the figures to designate similar or equivalent elements. The figures are not drawn to scale and they are provided merely to illustrate aspects disclosed herein. Several disclosed aspects are described below with reference to non-limiting example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the embodiments disclosed herein. One having ordinary skill in the relevant art, however, will readily recognize that the disclosed embodiments can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operations are not shown in detail to avoid obscuring aspects disclosed herein. The embodiments are not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the embodiments.
Notwithstanding that the numerical ranges and parameters setting forth the broad scope are approximations, the numerical values set forth in specific non-limiting examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein. For example, a range of “less than 10” can include any and all sub-ranges between (and including) the minimum value of zero and the maximum value of 10, that is, any and all sub-ranges having a minimum value of equal to or greater than zero and a maximum value of equal to or less than 10, e.g., 1 to 4.
Embodiments disclosed herein are directed to a method that facilitates forensic data recovery. The embodiments include a method which facilitates a process wherein the physical block address (PBA) and logical block address (LBA) memory spaces are examined to identify and collect hidden data without having to reverse engineer the algorithms in the Solid state drives (SSDs)(SSD used herein as an abbreviation for a single Solid state drive), by providing a hash value that is tolerant of a small percentage of bit errors in the source data.
The term “hidden data” and/or the plural form of this term are used throughout herein to refer to data stored on a SSD that is not accessible through the SSD's host computer interface, and the like.
FIG. 2 shows a block diagram of LBA data used to construct an Adelson-Velsky and Landis' (AVL) tree. The AVL tree 113 is a self-balancing binary search tree. In the AVL tree 113 , the heights of the two child subtrees of any node 114 differ by at most one. If at anytime they differ by more than one node, rebalancing is done to restore this property. The LBA image 110 is composed of 512-byte sectors 111 . The LBA image 110 and a PBA image 120 , discussed further below, consist of a linear array of sectors. Each sector 111 is examined and a special hash value 112 is computed, called an Error Tolerant Cyclic Redundancy Check (ETCRC), described in detail further below. Based on the value of the ETCRC, a node 114 is either inserted (if a node of that value is not present) or updated in the AVL tree 113 . This process creates a tree 113 which is quickly searchable by ETCRC value, and is much smaller than the LBA image 110 .
It is possible that two sectors will have the same data, and therefore the same ETCRC values, and will indicate the same node of the tree. To track all the sectors with the same ETCRC, each tree node contains a linked list of associated LBA sector information, comprised of the byte offset of each sector within the LBA image 110 , and a Cyclic Redundancy Check (CRC) of each sector, typically a standard 32-bit CRC such as the CRC32 (commonly used in Ethernet).
FIG. 3 shows a completed AVL tree 113 , and each of several unique nodes 114 is shown with a unique linked list 152 . The completed AVL tree 113 is searchable by ETCRC value. Once the corresponding node is found, the associated linked list discloses the entire set of LBA sectors having that ETCRC value, and the 32-bit CRC of each.
FIG. 4 shows a block diagram of PBA data used in conjunction with the LBA AVL tree. To identify hidden data in the PBA image 120 , the ETCRC 122 of each PBA sector 121 is searched for in the tree 113 , and sectors not found are considered hidden. As illustrated in this embodiment, the PBA image 120 is composed of 512-byte sectors 121 . The ETCRC values 122 are computed for each sector in the image 120 . A search of the LBA AVL tree 113 is performed using the ETCRC value 122 . If the search fails, the PBA sector does not appear in the LBA image 110 , and the PBA sector is output to a file as hidden data. If the search succeeds, the linked list 152 , as shown in FIG. 3 , associated with the tree node is searched and the CRCs of the PBA sector and LBA sector are compared. If a match is not found, the PBA sector is output to a file as hidden data.
The inventors have found that this process works well, with the stated assumption that the errors present in the PBA image 120 have been corrected. If they have not been corrected, then any bit errors in the PBA sector source data will foul the hash and CRC values and prevent matches to corresponding LBA sectors.
More specifically, if bit errors in the PBA image 120 are not corrected, hash values computed on corresponding LBA sectors will not match. What is needed is a hash value that is tolerant of some small percentage of bit errors in the source data. This operation is antithetical to the standard definition of a hash function, where the hash value should change greatly with only one bit change in the source data.
FIG. 5 shows a block diagram of ETCRC byte (subfield) relationship to byte subsets in sectors. The ETCRC substantially serves the function of a hash, but is tolerant of some bit errors in the source data in that one bit change in the source data changes at most eight bits of the ETCRC. The ETCRC 161 is an 8-byte quantity that covers a 512-byte sector of data 160 . Each byte 162 in the ETCRC is an 8-bit CRC (generator polynomial x 8 +x 7 +x 4 +x 2 +x+1) covering a 64-byte subset 163 of the 512-byte sector. Thus, if there are bit errors in only two 64-byte subsets, the entire ETCRC will not change, but only two component bytes. Two ETCRCs which match partially imply that the source data matches except for some bit differences in a certain area or areas. The final quality of the match can be determined by comparing the two corresponding source data sets byte for byte.
The ETCRC 161 can have a format and size suited to the task, not only eight bytes, but more or fewer, to accommodate various sizes of data to be hashed. Furthermore, the components of the ETCRC 161 can be other than 8-bits in length, as demanded by project requirements. Though the generator polynomial, x 8 +x 7 +x 4 +x 2 +x+1, was chosen, other generator polynomials may be used. The inventors found that the generator polynomial produces an acceptable collision rate of ˜1E-3.
By using the ETCRC 161 as explained above, if there are uncorrected bit errors in a PBA sector, then the LBA and PBA ETCRC values 112 , 122 will not match, but usually only in one or two bytes of the ETCRC value. This is handled by a process called puncturing, which involves selectively ignoring combinations of bytes within the ETCRC during the hidden data discovery process.
FIG. 6 shows a representation of a PBA and an LBA ETCRC during the puncturing process. As shown, the PBA and LBA ETCRC match except for one byte, the fourth from the left. The puncturing process sequentially sets corresponding bytes in the LBA and PBA ETCRC values to zero. When a byte pair 180 is set to zero, the ETCRCs still do not match. However, in the sequential process, when a byte pair 181 is set to zero, the ETCRC values match. This event indicates that the LBA and PBA sector data is mostly matching, and may only mismatch by one or a few bits, prompting a deeper look at these sectors to determine the magnitude of the mismatch.
The discovery process is run the first time with the full ETCRCs as computed. Once the first pass is complete, the hidden data output file contains all the PBA sectors that do not appear in the LBA, but also many falsely mismatched sectors that are different simply because of a few bit errors. The hidden data set is then run through the process again, but with each hidden sector ETCRC value punctured, as shown in FIG. 6 , and with a modification of the LBA AVL tree 113 using punctured ETCRC values.
Puncturing may be performed using combinations of one, two, or more bytes of the ETCRC. To accommodate sectors with just a few bit errors in one 64-byte subset of the 512-byte sector, a single byte of the eight in an ETCRC is set to zero. There are eight such ETCRC puncturing patterns. To accommodate sectors with bit errors in two 64-byte subsets, two bytes of the eight in an ETCRC are set to zero. There are C(8, 2)=28 such ETCRC puncturing patterns. This level of puncturing is typically good enough to recover the vast majority of hidden data in the presence of PBA errors, though higher levels could certainly be used.
For convenience, the patterns used to puncture ETCRCs may be tabulated for use in the hidden data discovery process. As a non-limiting example, FIG. 12 , shows such a table of puncturing patterns. There are 37 puncturing patterns ( 400 and 401 ) shown. In each pattern, there are eight digits. A zero in the pattern indicates a punctured byte in an eight-byte ETCRC value. A sample pattern 402 (01011111) indicates puncturing of the left most and third from left bytes in an ETCRC value.
The entire hidden data discovery process is shown in flowchart form in FIGS. 7-11 . More specifically, FIGS. 7 through 11 collectively depict a flowchart of an embodiment of a method for identifying and recovering data that is normally hidden in NAND flash memory arrays in SSDs and is normally inaccessible using host computer interfaces, without having to reverse engineer the algorithms in the SSD, using a hash value that is tolerant of some small percentage of bit errors in the source data. In general, the inputs to this process are the LBA and PBA images, a DATA CORRECTED flag indicating whether the PBA image is error corrected, a tolerable error rate LIMIT if uncorrected, and a table containing ETCRC puncturing patterns. Regarding the table, a non-limiting example is shown and was discussed above with respect to FIG. 12 where the first entry indicates no puncturing, which is called an “empty pattern” in the flowchart 700 .
FIG. 7 shows a flowchart of a method. FIG. 7 starts the method 700 with a subroutine call, at 300 , to build the AVL tree. This subroutine is shown in more detail in FIG. 9 and is described further below. Generally, the LBA image 110 is scanned and an AVL tree 113 is built, suitable for searching using the ETCRC values computed from the data in the PBA image 120 . Next, the PBA image is opened, at 301 , as the file variable INPUTFILE. An operation, at 302 , sets PUNCTURE_INDEX to zero, and this value indexes the table of puncture patterns in the process. The top of the main loop is marked with connector “B.”
Within the main loop, the first main task 303 - 305 is to put the AVL tree 113 into a compatible format, depending on the puncturing pattern selected. If the pattern is “empty”, meaning no puncturing is occurring (line 1 in the table of FIG. 12 ), then the LBA AVL tree 113 is copied, at 305 , to a working tree and used as-is. If puncturing is occurring, then a subroutine “COPY LBA AVL TREE AND PUNCTURE”, at 304 , is called, which copies the LBA AVL tree 113 to the working tree while puncturing the ETCRC values and ensuring the tree meets the well-known AVL tree criteria. This step, at 304 , is disclosed in further detail below with respect to FIG. 10 . The hidden data output file is then opened, at 306 , as the last operation in FIG. 7 .
The flowchart 700 continues in FIG. 8 with a call to a subroutine, at 307 , “PROCESS INPUTFILE SECTORS.” This subroutine reads sectors from INPUTFILE and searches for them in the working AVL tree 113 , outputting hidden sectors to OUTPUTFILE. This subroutine is described in detail further below with respect to FIG. 11 .
An operation, at 308 , closes the INPUTFILE and OUTPUTFILE files after all sectors are processed. If the PBA data is correct as supplied, a decision, at 309 , terminates the process as no puncturing is required to complete hidden data discovery. If the PBA data is not correct as supplied, the PUNCTURE_INDEX is incremented, at 310 , and tested, at 311 , for maximum value, terminating the process if so. Else, the INPUTFILE is closed, and the OUTPUTFILE is reopened as the new INPUTFILE, at 312 , feeding the latest hidden data back into the process for further examination with a different puncturing pattern. This completes the description of the main loop in FIGS. 7 and 8 .
FIG. 9 shows the subroutine that builds the LBA AVL tree, at represented in general at step 300 . Generally, the LBA image 110 is scanned and the AVL tree 113 is built, suitable for searching using the ETCRC values computed from the data in the PBA image 120 .
An empty working tree is created, at 330 , first, and the LBA image 110 is opened, at 331 , as INPUTFILE. The top of the loop in this subroutine reads, at 332 , a sector of data from INPUTFILE. The ETCRC and CRC values are computed, at 333 . The ETCRC is searched for, at 334 in the tree. If not found, a node corresponding to the ETCRC is inserted, at 326 into the tree 113 .
The node in the tree corresponding to the ETCRC then has the INPUTFILE byte offset and CRC of the sector stored, at 337 , into the linked list. A decision block, at 338 , at the end of the loop terminates the loop after the last LBA sector has been examined. The INPUTFILE is then closed, at 339 .
The LBA AVL tree is now ready for use. FIG. 10 shows a subroutine “COPY LBA AVL TREE AND PUNCTURE”, as originally identified at step 304 . This subroutine copies the LBA AVL tree 113 to the working tree while puncturing the ETCRC values and ensuring the tree meets the well-known AVL tree criteria. An empty working tree, at 320 , is created first. The top of the loop in this subroutine reads an LBA tree node ETCRC value, at 321 , then punctures, at 322 , that value according to the current PUNCTURE INDEX table indexed puncture pattern. That punctured ETCRC is searched for, at 323 , in the working tree. If not found, the ETCRC is inserted, at 325 , into the tree.
The node in the working tree corresponding to the punctured ETCRC then is updated, at 326 , with a reference to the linked list from the original LBA AVL tree 113 . The puncturing process can have the effect of combining two or more LBA AVL tree nodes 114 . Rather than copying all the linked lists associated with those nodes into the working tree, references to the original LBA tree tables are stored, saving memory. A decision block, at 327 , at the end of the loop terminates the loop after the last LBA node has been loaded into the working tree.
FIG. 13 shows a block diagram of an AVL tree labeled with sample ETCRC values. The embodiment in FIG. 13 is a non-limiting example. As shown, four digits are provided in each node for the sake of discussion and brevity. A node 130 is shown containing the decimal value 4713 .
FIG. 14 shows the information after puncturing and rebalancing of the AVL tree. The third digit from the right in each number has been punctured by replacing it with a zero. For the FIG. 14 values 4713 , 4513 , and 4313 , the puncturing process makes them all identical, at a value of 4013 . The node 140 takes on this value. This node also carries with it references to the linked lists from the three original nodes in FIG. 13 (reference not shown). The net effect is that the punctured and rebalanced tree in FIG. 14 produces more search hits on similarly punctured ETCRC values, increasing the likelihood of finding a match among LBA and PBA sectors that differ in only a few bits.
FIG. 11 shows a subroutine “PROCESS INPUTFILE SECTORS”. This subroutine was provided for at 307 in FIG. 8 . This subroutine reads sectors from INPUTFILE and searches for them in the working AVL tree, outputting hidden sectors to OUTPUTFILE. At the top of the loop in this subroutine, a sector S is read, at 350 , from the INPUTFILE, and INPUTFILE is either the PBA image 120 or a subsequent hidden data file. The ETCRC and CRC are computed, at 351 , on the sector S. The ETCRC value is punctured, at 352 , according to the current tabulated puncture pattern and specified by PUCNTURE_INDEX. That punctured ETCRC is searched for, at 353 , in the working tree. If not found, the sector S is written, at 360 , to the hidden data output file. If found, the node's linked list (or multiple lists in the case of a punctured-ETCRC based working tree) is searched, at 355 , for the CRC of sector S. If found, at 356 , the sector is not a hidden data sector and execution falls to the bottom of the loop, at 361 . If the CRC indicates a mismatch, the disposition of sector S depends on the corrected status, at 357 , of the PBA image 120 . If the PBA is corrected, then a CRC mismatch indicates a data mismatch and sector S is written, at 360 , to the hidden data output file. If the PBA is uncorrected, then the LBA sector data is compared, at 358 , with sector S byte for byte. The fraction of mismatch (bits not matching divided by total bits in the sector) is compared, at 359 , against the specified mismatch LIMIT. A mismatch causes sector S to be written, at 360 , to the hidden data output file. The bottom of this subroutine's loop checks, at 361 , to see if all sectors in INPUTFILE have been processed, looping if not, returning to the caller if so.
After isolation of the hidden data, commercial tools can be applied to identify interesting information, such as word processing documents, spreadsheets, videos, and images.
FIG. 15 shows a block diagram of an embodiment of a device. The device 1500 comprises an interface 1510 to access memory space on a memory device, such as, but not limited to, a memory array on the SSD. A graphics processing unit 1520 , or simply a processing unit, is also provided to create a plurality of hash values for a logical block address (LBA) memory space of the memory device and to create a plurality of hash values for a physical block address (PBA) memory space of the memory to identify data hidden within the PBA memory space from view of the LBA memory space. A display 1530 , or output device, is also provided to show the located hidden data. The display may be a visual display or may produce a printout with information pertaining to the hidden data. Thus, the term display is not used herein to be considered limiting.
Thus, as also disclosed above creating the hash value for both the LBA and PBA memory spaces comprises creating an error tolerant cyclic redundancy check (ETCRC) table for both the LBA memory space and PBA memory space.
The disclosed embodiments are conformable to parallel processing on a graphics processing unit (GPU). The ETCRC process is performed on each LBA and PBA sector independently and therefore may be paralleled. Furthermore, the matching process for each LBA sector may be paralleled. The embodiments may be designed to allow for extensive parallelism and commensurate acceleration.
As another non-limiting example, the embodiments disclosed herein may be used with the on-board chip reader adapter disclosed in U.S. patent application Ser. No. 14/716,866, which claims priority to U.S. Provisional Application 62/000,475 filed May 19, 2014, both which are incorporated herein by reference in its entirety
Even though the disclosed embodiments do not match the PBA and LBA sectors the same way that the SSD FTL software would, it does not matter because the output that is valuable is the unique, hidden PBA data, without regard for the PBA/LBA mapping relationship maintained by the FTL. Specifically, as a non-limiting example, for four PBA sectors containing data values A, B, B, and C, with the LBA showing sectors with values A, B, and C, an embodiment disclosed herein outputs as hidden data one sector with data value B. It does not matter what the PBA/LBA mapping was for that sector. It only matters that a sector with that value was recovered from the hidden PBA space. This is advantageous in that a determination of the PBA/LBA mapping relationship is not required, which is different for most types of SSD and FTL algorithms.
Several general advantages of this invention include, but are not limited to the following: hidden data is discovered, data not accessible over the usual computer interface for the storage device; only the most basic knowledge of the storage format is required, and no information about the FTL mapping between LBA to PBA; knowledge of the error correction methods is optional, and the error tolerant cyclic redundancy check makes hidden data discovery possible in a reasonable time frame; identification of the hidden data is accomplished in a reasonable amount of time, using a reasonable amount of storage that is approximately about 10% of the size of the LBA image.
While various aspects of the present disclosure have been described above, it should be understood that they have been presented by way of example and not limitation. It will be apparent to persons skilled in the relevant art(s) that various changes in form and detail can be made therein without departing from the spirit and scope of the present disclosure. Thus, the present disclosure should not be limited by any of the above described exemplary aspects.
In addition, it should be understood that the figures in the attachments, which highlight the structure, methodology, functionality and advantages of the present disclosure, are presented for example purposes only. The present disclosure is sufficiently flexible and configurable, such that it may be implemented in ways other than that shown in the accompanying figures (e.g., implementation within computing devices and environments other than those mentioned herein). As will be appreciated by those skilled in the relevant art(s) after reading the description herein, certain features from different aspects of the method of the present disclosure may be combined to form yet new aspects of the present disclosure.
Further, the purpose of the foregoing Abstract is to enable the U.S. Patent and Trademark Office and the public generally and especially the scientists, engineers and practitioners in the relevant art(s) who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of this technical disclosure. The Abstract is not intended to be limiting as to the scope of the present disclosure in any way. | A method of isolating hidden data in a solid state memory system is disclosed including obtaining a logical block address (LBA) image from the memory system, obtaining a physical block address (PBA) image, determining whether an error exists in the PBA image and correcting the error, calculating an ETCRC on each sector of the LBA image and building a search tree indexed on the ETCRC value. For each sector in the PBA image, the method also includes computing an error tolerant cyclic redundancy check (ETCRC) value and searching for the ETCRC value in the LBA search tree. If the ETCRC value is found, also included is comparing the cyclic redundancy check (CRC) of the LBA and PBA sectors, and outputting to an output file the PBA sector as hidden data if either the ETCRC value is not found in the LBA search tree or the CRC comparison fails. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a motor-driven compressor and, more particularly, to a motor driven compressor for an air conditioning system where the compressor is cooled by refrigerant gas.
In the prior art, a compressor is usually incorporated in an automotive air conditioning system, and it is known to employ a motor-driven compressor in an automotive air conditioner.
Such a compressor is disclosed in Japanese Patent Provisional Publications No. 5-187356. This compressor is a swash type compressor that includes an electric motor and a refrigerant compressing device in a common housing. The electric motor is located in one part of the internal space of the housing, and the refrigerant compressing device is received in the remaining part of the housing. The electric motor and the refrigerant compressing device are arranged in the housing in a tandem relationship. The refrigerant compressing device includes cylinder bores, pistons located in the respective cylinder bores, a drive shaft and a swash plate coupled to the drive shaft for converting a rotational motion of the drive shaft to linear piston motion. A portion of the drive shaft supports a rotor of the electric motor. When the pistons slide within the cylinder bores, refrigerant is drawn into the cylinder bores. Compressed refrigerant is exhausted into an exhaust chamber. The electric motor is cooled by blow-by gases exhausted in an inner part of the housing and by heat dissipation through the walls of the housing. However, when the electric motor generates a large quantity of heat, the electric motor is not sufficiently cooled, which reduces a magnetic flux in the electric motor and reduces the motor's efficiency.
Japanese Patent Provisional Publication No. 9-32729 discloses a scroll type compressor driven by an electric motor. In such a compressor, the electric motor and a refrigerant compressing device are located in first and second chambers of a common housing. Although the common housing has a partition wall between the electric motor and the refrigerant compressing device, the first and second chambers communicate with each other through a passage formed in the partition wall. An intake port is formed in the first chamber, and an exhaust port is formed in the second chamber. When the refrigerant compressing device is driven by the electric motor, refrigerant is drawn from the intake port into the refrigerant compressing device through the electric motor and the passage formed in the partition wall, compressed by the refrigerant compressing device, and exhausted from the exhaust port. The electric motor is cooled by refrigerant passing through a space between a stator and a rotor of the electric motor. In such a compressor, however, if the electric motor generates a large quantity of heat if the electric motor is operating under a high load, the temperature of the refrigerant becomes high with a resultant decrease in the compression efficiency.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a compressor that can effectively cool an electric motor in a highly reliable manner.
To achieve the above and other object, the present invention provides a compressor having an interior refrigerant passage. The refrigerant gas is supplied to the interior refrigerant passage from an external refrigerant circuit. The compressor comprises a housing, a cylinder bore disposed in the housing. A first chamber is disposed in the housing and communicates to the cylinder bore. A second chamber is disposed in the housing. The second chamber is partitioned from the first chamber in an air tight manner. A piston is movably located in the cylinder bore. A drive mechanism is disposed in the first chamber to move the piston. A motor is disposed in the second chamber to drive the drive mechanism. A refrigerant path connects the second chamber with the interior refrigerant passage.
Other aspect and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a cross sectional view of a first preferred embodiment of a compressor according to the present invention;
FIG. 2 is a cross sectional view taken along line 2 — 2 of FIG. 1;
FIG. 3 is a cross sectional view of another preferred embodiment of a compressor according to the present invention;
FIG. 4 is cross sectional view taken along line 4 — 4 of FIG. 3;
FIG. 5 is a cross sectional view of a third preferred embodiment of a compressor according to the present invention; and
FIG. 6 is a cross sectional view taken along line 6 — 6 of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIGS. 1 and 2 show a preferred embodiment of a compressor according to the present invention.
As shown in FIG. 1, the compressor includes a housing 10 . The housing 10 includes a motor housing component 11 , a front housing component 12 , cylinder block 13 and a rear housing component 14 . The components 11 , 12 , 14 and the cylinder block 13 are aligned along an axis of the compressor, and they are coupled to one another by a plurality of connecting rods (not shown), and adjacent components are sealed with an “O” ring. An inner part of the motor housing component 11 has a motor chamber 15 , and an inner part of the front housing component 12 has a swash plate chamber 16 . The motor chamber 15 and the swash plate chamber 16 are separated by a partition wall 12 A of the front housing component 12 .
An electric motor 21 is incorporated in the motor chamber 15 , and a refrigerant compressing device is incorporated in the front housing component 12 , the cylinder block 13 and the rear housing components 14 such that a part of the compressing device is exposed to the swash plate chamber 16 . The refrigerant compressing device includes first and second cylinder bores 13 A, 13 B, first and second pistons 26 , 27 , a valve unit 30 , an intake chamber 31 , an exhaust chamber 33 , an intermediate pressure chamber 32 , a drive shaft 17 and a swash plate 22 .
The drive shaft 17 and the swash plate 22 form a drive mechanism of the refrigerant compressor device. The drive shaft 17 extends through the partition wall 12 A of the front housing component 12 . One end of the drive shaft 17 is supported by an end wall 11 B of the motor housing component 11 , and the other end of the drive shaft 17 is supported by the cylinder block 13 . More specifically, the drive shaft 17 is held at one end by a radial bearing 18 A located in the end wall 11 B of the motor housing component 11 . The other end is held by a radial bearing 18 B located in a cavity 13 C of the cylinder block 13 . An axial seal 12 C is located in the end wall 12 A to seal between a through-bore of the end wall 12 A and the drive shaft 17 , which prevents leakage of compressed refrigerant between the motor chamber 15 and the swash plate chamber 15 .
The electric motor 21 includes a stator 19 and a rotor 20 . The stator 19 is fixed to the motor housing component 11 , and the rotor 20 is fixed to the drive shaft 17 .
The swash plate 22 is located in the swash plate chamber 16 . The swash plate 22 is fixed to the drive shaft 17 . A thrust bearing 23 is placed between the swash plate 22 and the end wall 12 A of the front housing component 12 . One of the drive shaft 17 extends in the cylinder block 13 and is urged toward the electric motor 21 by a dish spring 24 . A spring seat is located in the cavity 13 C of the cylinder block 13 . The drive shaft 17 is positioned in the axial direction by the thrust bearing 23 and the dish spring 24 .
The cylinder block 13 has a first cylinder bore 13 A and a second cylinder bore 13 B. The second cylinder bore 13 B is smaller in diameter than the first cylinder bore 13 A. The cylinder bores 13 A and 13 B are formed in the cylinder block 13 in a symmetrical relationship relative to the rotational axis of the drive shaft 17 and are angularly spaced from one another by 180 degrees. The cylinder bores 13 A and 13 B accommodate first and second pistons 26 , 27 , respectively. The cylinder bores 13 A and 13 B have compression chambers 13 E, 13 F, the volumes of which vary in dependence on the stroke of the pistons 26 , 27 . The ends of the pistons 26 , 27 have concave portions 26 A, 27 A, which accommodate pairs of engaging shoes 28 , 29 , respectively. The peripheral edge of the swash plate 22 is held between the shoes 28 , 29 of each pair. Consequently, when the drive shaft 17 rotates, the swash plate 22 rotates with the drive shaft 17 , which causes the pistons 26 , 27 to reciprocate. Each of the pistons 26 , 27 has a stroke defined by the inclined angle of the swash plate 22 . In the compressor shown in FIG. 1, as the swash plate 22 rotates, the upper piston 26 slides (as viewed in FIG. 1) from a top dead center position, which is shown in FIG. 1, toward a bottom dead center position, and the other piston 27 slides from the bottom dead center position, which is shown in FIG. 1, toward the top dead center position.
The rear housing component 14 forms the intake chamber 31 , the intermediate pressure chamber 32 and the exhaust chamber 33 . The intake chamber 31 , the exhaust chamber 33 and the intermediate pressure chamber 32 communicate with the cylinder bore 13 A, the cylinder bore 13 B, and the cylinder bores 13 A and 13 B, respectively, through a valve unit 30 .
An external refrigerant circuit 50 includes a condenser, an expansion valve and an evaporator and forms part of a refrigerant circuit with the compressor. The intake chamber 31 is connected through a downstream conduit 51 to an outlet of the evaporator, and the exhaust chamber 33 is connected through an upstream conduit 52 to an inlet of the condenser. An intake port 31 A and an exhaust port 33 A are formed in the rear housing component 14 in communication with the intake chamber 31 and the exhaust chamber 33 , respectively. The downstream conduit 51 communicates through the intake port 31 A with the intake chamber 31 , and the upstream conduit 52 communicates through the exhaust port 33 A with the exhaust chamber 33 .
The valve unit 30 is located between the cylinder block 13 and the rear housing component 14 . The valve unit 30 has an intake valve forming member 34 and a port forming member 35 .
As shown in FIG. 2, the port forming member 35 has ports 35 A, 35 B, 35 C and 35 D. The port 35 A communicates with the intake chamber 31 and the cylinder bore 13 A, and the port 35 B communicates with the cylinder bore 13 A and the intermediate pressure chamber 32 . The port 35 C communicates with the intermediate pressure chamber 32 and the cylinder bore 13 B, and the port 35 D communicates with the cylinder bore 13 B and the exhaust chamber 33 . A port 35 E communicates with a communication passage 38 , and a cooling passage 39 communicates with the intermediate chamber 32 and the swash plate chamber 16 . The intake valve forming member 34 has intake valves to open or close the ports 35 A, 35 C. The intake valves that open or close the ports 35 B, 35 D include first and second leaf valves 36 A, 36 B, respectively. The first leaf valve 36 A is supported by a retainer 37 A to open or close the port 35 B and is connected to the intake valve forming member 34 and the port forming member 35 by a pin 30 A. The second leaf valve 36 B is supported by a retainer 37 B to open or close the port 35 D and is connected to the intake valve forming member 34 and the port forming member 35 .
In FIG. 1, the compressor also includes a cooling circuit for cooling the electric motor 21 . The cooling circuit includes a conduit 51 A, which branches from the downstream conduit 51 , and a cooling passage 39 , which extends between the motor chamber 15 and the intake chamber 31 . As best seen in FIG. 2, the cooling passage 39 is formed in a projection 14 A protruding from the outer surface of the rear housing component 14 . The projection 14 A is integrally formed with the rear housing component 14 . The cylinder block 13 and the front housing component 12 also have a projection contiguous with the projection 14 A of the rear housing component 14 . The projection of the cylinder block 13 and the front housing component 12 is parallel to the drive shaft 17 . Further, the outer surface of the front housing component 11 has a projection contiguous with the projections of the cylinder block 13 and the front housing component 12 . The cooling passage 39 extends through these projections and communicates at one end with the motor chamber 15 and at the other end with the intake chamber 31 .
The end wall 11 B of the motor housing component 11 has an intake port 31 B. The intake port 31 B communicates with a cavity 11 A. The conduit 51 A is connected through the intake port 31 B with the motor chamber 15 .
The operation of the compressor will now be described in a case where the refrigerant includes a mixture of carbon dioxide and lubricating oil.
When the electric motor 21 rotates the drive shaft 17 , the swash plate 22 rotates with the drive shaft 17 . When this occurs, the pistons 26 , 27 reciprocate in the cylinder bores 13 E, 13 F, respectively. Due to the reciprocating motion of the piston 26 , the volumes of the compression chambers 13 E, 13 F vary, thereby repeatedly drawings, compressing and exhausting the refrigerant in a sequential manner.
When the first piston 26 moves toward the bottom dead center position, the refrigerant flowing from the outlet of the evaporator of the refrigerant circuit 50 is drawn into the compression chamber 13 E through the intake chamber 31 and the port 35 A. When the first piston 26 moves toward the top dead center position, the refrigerant is compressed in the compression chamber 13 E. The compressed refrigerant is then exhausted to the intermediate pressure chamber 32 through the leaf valve 36 A and the port 35 B.
At this instant, since the second piston 27 begins to move toward the bottom dead center position, some of the refrigerant exhausted to the intermediate pressure chamber 32 is drawn into the second compression chamber 13 F through the port 35 C. As the second piston 27 moves toward the top dead center position, the refrigerant in the second compression chamber 13 F is re-compressed. The compressed refrigerant is exhausted to the exhaust chamber 33 through the leaf valve 36 B and the port 35 D. The compressed refrigerant is then delivered to the condenser of the refrigerant circuit 50 through the exhaust port 33 A and the conduit upstream 52 .
The reminder of the refrigerant in the intermediate pressure chamber 32 flows into the swash plate chamber 16 through the port 35 E and the communication passage 38 . Thus, the pressure in the swash plate chamber 16 equals that of the intermediate pressure chamber 32 . The radial bearing 18 B is lubricated with lubricating oil flowing into the swash plate chamber 16 with the refrigerant.
On the other hand, evaporated refrigerant in the conduit 51 delivered from the outlet of the evaporator of the refrigerant circuit 50 flows into the intake port 31 B through the conduit 51 A. This evaporated refrigerant flows into the motor chamber 15 through a space between inner and outer races of the radial bearing 18 A. When this happens, the radial bearing 18 A is lubricated with lubricating oil that is dispersed in mist form in the refrigerant.
Further, the refrigerant in the motor chamber 15 flows through a space between the stator 19 and the rotor 20 , thereby cooling the electric motor 21 . Subsequently, the refrigerant flows through the cooling passage 39 into the intake chamber 31 . Then, the refrigerant is drawn into the compression chamber 13 E, together with refrigerant that entered the intake chamber 31 through the downstream conduit 51 , and is compressed.
The compressor of the present invention provides numerous advantages over the prior art compressors as discussed below.
Some evaporated refrigerant flowing from the outlet of the evaporator of the refrigerant circuit 50 is delivered to the motor chamber 15 , which cools the electric motor 21 . As a result, even when the compressor is driven at a high speed and the electric motor 21 is operating under high load, the temperature of the electric motor 21 is limited, and a reduction in the magnetic flux of the electric motor 21 due to high temperatures is avoided.
The refrigerant in the intermediate pressure chamber 32 flows into the swash plate chamber 16 such that the pressure in the swash plate chamber 16 is maintained at an intermediate pressure that is equal to that of the intermediate pressure chamber 32 . That is, the pressure acting on the head of the piston 26 is nearly equal to that acting on the opposite end of the piston 26 . Accordingly, the pressure difference acting on opposing ends of the pistons 26 , 27 is minimum in the course of the exhausting step, in which the pistons 26 , 27 operate under the highest load, which reduces forces and friction acting on various parts such as the pistons 26 , 27 , the shoes 28 , 29 , the swash plate 22 , the drive shaft 17 and the thrust bearing 23 . This extends the life of the compressor and reduces noises. Also, the amount of blow-by gas is decreased, which improves the compressing performance.
During the intake stroke of the first piston 26 , the compression chamber 13 E draws a mixture of refrigerant directly introduced to the intake chamber 31 through the intake port 31 A and refrigerant that entered the intake chamber 31 after passing through the intake port 31 B and the motor chamber 15 . That is, refrigerant that is heated in the motor chamber 15 is mixed with refrigerant directly drawn from the refrigerant circuit 50 , which has a low temperature. Accordingly, the compression chamber 13 E is filled with the refrigerant having a small specific volume, which improves efficiency.
The seal member 12 C seals between the bore 12 B and the drive shaft 17 such that refrigerant does not flow between the motor chamber 15 and the swash plate chamber 16 . This improves the performance of the compressor.
The refrigerant that enters the intake port 31 B flows through spaces between the inner and outer races of the thrust bearing 18 A into the motor chamber 15 , thereby cooling the thrust bearing 18 A while lubricating the thrust bearing 18 A with lubricating oil in mist form, which is carried by the refrigerant. As a result, the life of the bearing is extended.
The refrigerant that enters the motor chamber 15 through the intake port 31 B passes through the space between the stator 19 and the rotor 20 , and cools a large area of the electric motor 21 in a highly reliable manner.
Another preferred embodiment of a compressor according to the present invention is shown in FIGS. 3 and 4, and like parts bear the same reference numerals as those used in FIGS. 1 and 2.
In this preferred embodiment, the compressor is a swash type multi-stage compressor for use in a refrigerant circuit that uses refrigerant mixed with carbon dioxide. All the evaporated refrigerant flowing from the extended refrigerant circuit is initially delivered to a motor chamber and is subsequently compressed.
A housing 10 includes a motor housing component 11 , a front housing component 12 , a cylinder block 13 and a rear housing component 14 . A motor chamber 15 is formed in the motor housing component 11 , and a swash plate chamber 16 is formed in the front housing component 12 . The motor chamber 15 and the swash plate chamber 16 are separated from one another by an end wall 12 A. An electric motor 21 is accommodated in the motor chamber 21 , and a compressing device is accommodated in the front housing component 12 .
The compressing device includes a cylinder 13 A, a cylinder bore 13 B, pistons 26 , 27 , which are located in the cylinder bores 13 A, 13 B, respectively, a drive mechanism, which includes a drive shaft 17 and a swash plate 22 fixed on the drive shaft 22 , an intake chamber 31 , which is connected with the cylinder bore 13 A, an exhaust chamber 33 , which is connected with the cylinder bore 13 B, an intermediate chamber 32 , which is connected with both the cylinder bores, and a valve unit 30 , which includes ports and valves for permitting compressed refrigerant to flow into the cylinder bore 13 B through the intermediate pressure chamber 32 and for permitting re-compressed refrigerant to flow into the exhaust chamber 33 .
The exhaust port 33 A is formed in the rear housing component 14 and communicates with the exhaust chamber 33 . The intake port 31 B is formed in a peripheral wall of the motor housing component 11 . The electric motor 21 includes a stator 19 and a rotor 20 . The stator 19 is fixed to the motor housing component 11 . The rotor 20 is carried by the drive shaft 17 in the motor chamber 15 .
In such a compressor, all the refrigerant flowing from the external refrigerant circuit 50 is delivered to the motor chamber 15 and, thereafter, the refrigerant is compressed by the pistons 26 , 27 . Then, the compressed refrigerant is exhausted into the external refrigerant circuit 50 . To this end, the outlet side of the evaporator of the circuit 50 is connected with the motor chamber 15 through the conduit 51 and the intake port 31 B. An inlet of the condenser of the external refrigerant circuit 50 is connected with the exhaust chamber 33 through the conduit 52 .
Also, the motor chamber 15 is connected with the intake chamber 31 through the drive shaft 17 and a passage formed in the cylinder block 13 . The motor chamber 15 and the intake chamber 31 are connected with each other through a passage including a communication bore 17 A, a relay chamber 13 G and a communication bore 13 H. One end of the communication bore 17 A opens to the motor chamber 15 . The other end of the communication bore 17 A opens to the relay chamber 13 G of the cylinder block 13 . The relay chamber 13 G is formed in the cylinder block 13 and is contiguous with a cavity 13 c , into which one end of the drive shaft 17 extends. Further, the cylinder block 13 includes the communication bore 13 H, which is connected to the relay chamber 13 G. One end of the communication bore 13 H opens to the relay chamber 13 G, and the other end of the communication bore 13 H opens, through a port 35 G of a port forming member 35 , to the intake chamber 31 as shown in FIG. 4. A seal 41 is located between the cavity 13 C and the drive shaft 17 , which seals between the cavity 13 C and the swash plate chamber 17 .
As shown in FIG. 3, the cylinder block 13 also includes the communication bore 40 . One end of the communication bore 40 opens to the swash plate chamber 16 , and the other end of the communication bore 40 communicates with the intermediate pressure chamber 32 through a port 35 H, which is formed inthe port forming member 35 .
In operation, when the electric motor 21 is turned on, the swash plate 22 rotates and the pistons 26 , 27 reciprocate. When this occurs, the refrigerant in the external refrigerant circuit 50 is drawn into the motor chamber 15 through the conduit 53 and the intake port 31 . The refrigerant in the motor chamber 15 flows through the space between the stator 19 and the rotor 20 of the electric motor 21 into the communication bore 17 A, from which the refrigerant flows through the relay chamber 13 G, the communication bore 13 H, and the port 35 G into the intake chamber 31 . Since the refrigerant is delivered to the relay chamber 13 G before it is compressed, the pressure in the relay chamber 13 G is lower than that of the swash plate chamber 16 . The seal 41 prevents leakage of the refrigerant into the relay chamber 13 G from the swash plate chamber 16 due to the pressure difference between the relay chamber 13 G and the swash plate chamber 16 .
The refrigerant in the intake chamber 31 is conducted into the first cylinder bore 13 A through the port 35 A and is compressed. The compressed refrigerant is then delivered to the intermediate pressure chamber 32 through the port 35 B. Then, refrigerant flows through the port 35 C into the cylinder bore 13 B and is re-compressed. The re-compressed refrigerant is exhausted through the port 35 D into the exhaust chamber 33 . The exhausted refrigerant is delivered to the condenser of the external refrigerant circuit 50 through the conduit 52 .
As seen in FIG. 3, since some of the refrigerant in the intermediate pressure chamber 32 flows into the swash plate chamber 16 through the port 35 H and the communication bore 40 , the swash plate chamber 16 has a pressure nearly equal to that of the intermediate pressure chamber 32 . The radial bearing 18 B is lubricated with the lubricating oil contained in the refrigerant that flows to the swash plate chamber 16 .
In the compressor discussed above, since the motor chamber 15 is supplied with evaporated refrigerant, which is low in temperature and is not compressed by the pistons 26 , 27 , from the external refrigerant circuit 50 , the electric motor 21 is cooled.
Further, since the swash plate chamber 16 has the intermediate pressure, which is nearly equal to that of the intermediate pressure chamber 32 , and since there is a minimum pressure difference between the fronts and backs of the pistons 26 , 27 during the exhausting stroke, in which the pistons are under the maximum load, forces and friction acting on parts such as the pistons 26 , 27 , the shoes 28 , 29 , the swash plate 16 , the drive shaft 17 , and the thrust bearing 23 are reduced, which extends the life of the compressor and reduces noise. Since the amount of blow-by gases decreases, the compressor has a higher compression efficiency.
Since, further, the seal 12 C seals the space between the bore 12 B and the drive shaft 17 , the refrigerant is prevented from leaking to the motor chamber 15 from the swash plate chamber 16 , which increases the compression efficiency.
Since the refrigerant in the motor chamber 15 passes through the space between the inner periphery of the stator 19 and the outer periphery of the rotor 20 , a large area of the electric motor 21 is cooled.
A further alternative preferred embodiment of a compressor according to the present invention is shown in FIGS. 5 and 6, and like parts bear the like reference numerals as those used in FIGS. 1 and 2.
In this alternative embodiment, the compressor is a swash type multi-stage compressor for use in a refrigerant circuit that uses refrigerant mixed with carbon dioxide. All the evaporated refrigerant flowing from the external refrigerant circuit is initially compressed by a refrigerant compressor, and is delivered to a motor chamber.
A housing 10 includes a motor housing component 11 , a front housing component 12 , a cylinder block 13 and a rear housing component 14 . A motor chamber 15 is formed in the motor housing component 11 , and a swash plate chamber 16 is formed in the front housing component 12 . The motor chamber 15 and the swash plate chamber 16 are separated from one another by an end wall 12 A. An electric motor 21 is located in the motor chamber 21 , and a compressing device is accommodated in the front housing component 12 . The cylinder block 13 and the rear housing component 14 such that a part of a drive mechanism is exposed to the swash plate chamber 16 .
The electric motor 21 includes a stator 19 and a rotor 20 . The stator 19 is fixed to the motor housing component 11 , and the rotor 20 is fixedly supported on the drive shaft 17 .
The compressing device includes a cylinder 13 A, a cylinder bore 13 B, pistons 26 , 27 , which are located in the cylinder bores 13 A, 13 B, respectively, a drive mechanism, which includes a drive shaft 17 and a swash plate 22 fixed on the drive shaft 22 , an intake chamber 31 , which is connected with the cylinder bore 13 A, an exhaust chamber 33 , which is connected with the cylinder bore 13 B, an intermediate chamber 32 , which is connected with both the cylinder bores, and a valve unit 30 , which includes ports and valves for permitting compressed refrigerant to flow into the cylinder bore 13 A from the intake chamber 31 for permitting compressed refrigerant to flow into the cylinder bore 13 B through the intermediate pressure chamber 32 to re-compress the refrigerant and subsequently introducing re-compressed refrigerant into the exhaust chamber 33 . The intake port 31 A is formed in the rear housing component 14 , and is connected with the intake chamber 31 , and the exhaust port 33 B is formed in the motor housing component 11 , and is connected with a cavity 11 A that accommodates a bearing 18 A.
The valve unit 30 includes an intake valve forming member 34 and a port forming member 35 . The intake valve forming member 34 has intake valves to open or close the ports 35 A, 35 C. As seen in FIG. 6, the port forming member 35 has ports 35 A, 35 B, 35 C, 35 D, 35 E, 35 J. The port 35 E is connected with a cooling passage 39 , that communicates with the intermediate chamber 32 and the swash plate chamber 16 as shown in FIG. 5 . The port 35 J communicates with the exhaust chamber 33 and the passage 42 .
The first and second leaf valves 36 A and 36 B are supported by retainers 37 A, 37 B to open or close the ports 35 B, 35 D and is connected to the intake valve forming member 34 and the port forming member 35 , respectively, by pins 30 A, 30 B.
In the alternative embodiment of the compressor, the intake chamber 31 is connected with the external refrigerant circuit 50 through the intake port 31 A and the conduit 56 . The exhaust chamber 33 is connected with the motor chamber 15 through the passage 42 . The motor chamber 15 is connected with an inlet of a condenser of the outer refrigerant circuit 50 .
A passage 42 is connected with the exhaust chamber 33 and the motor chamber 15 is located outside of the housing 10 in the same manner as the compressor of the first preferred embodiment shown in FIGS. 1 and 2. The passage 42 extends through an outward projection 14 A extending from the outer surface of the rear housing component 14 , outward projections formed the outer surfaces of the cylinder block 13 and the front housing component 12 , and an outward projection formed on the outer surface of the front housing component 11 . One end of the passage 42 opens to the port 35 J of the valve unit 30 , and the other end of the passage 42 opens to one end of the motor chamber 15 adjacent the swash plate chamber 16 .
In operation, when the electric motor 21 is turned on, the swash plate 22 rotates and the pistons 26 , 27 reciprocate. When this occurs, refrigerant in the external refrigerant circuit 50 is drawn into the intake chamber 31 through the intake port 31 A. As seen in FIG. 6, refrigerant is drawn through the port 35 A into the cylinder bore 13 A and is compressed therein. Compressed refrigerant is conducted through the port 35 B and the first leaf valve 36 A into the intermediate pressure chamber 32 . Then, the compressed refrigerant is conducted into the cylinder bore 13 B through the port 35 C and is re-compressed. The re-compressed refrigerant is delivered through the port 35 D and the second leaf valve 36 B to the exhaust chamber 33 . The compressed refrigerant is conducted through the port 35 J and the passage 42 into the motor chamber 15 . The refrigerant is delivered to the motor chamber 15 and flows through the space between the stator 19 and the rotor 20 and the space between the inner and outer races of the radial bearing 18 A into the exhaust port 33 B. Then, the refrigerant is returned to an inlet of the condenser of the external refrigerant circuit 50 through the conduit 54 . Consequently, the radial bearing 18 A is lubricated with the lubricating oil in mist form carried by the refrigerant.
As seen in FIG. 5, some of the refrigerant is conducted to the swash plate chamber 16 through the port 35 E and the communication passage 38 . When this occurs, the swash plate chamber 16 has an intermediate pressure, which is equal to that of the intermediate pressure chamber 32 . The radial bearing 18 B is lubricated with the lubricating oil carried by the refrigerant flowing to the swash plate chamber 16 .
The compressor of the alternative embodiment of FIG. 5 provides the following advantages:
The electric motor 21 is cooled by the compressed refrigerant before is exhausted into the external refrigerant circuit 50 . Since this compressed refrigerant is lower in temperature than the motor chamber 15 , the electric motor 21 is cooled.
Since, the compressed refrigerant flows into the motor chamber 15 through the passage 42 that extends through the projection formed on the outer surface of the housing 10 , the compressed refrigerant is cooled by outside air while passing through the passage 42 and cools the electric motor 21 .
It should be apparent to those skilled in the art that the present invention may be embodied in many other forms without departing from the spirit or scope of the invention. Particularly, it should be understood that the invention may be embodied in the following forms.
In the illustrated embodiments, although the motor chamber 15 is cooled by either evaporated refrigerant, which is not compressed, or compressed refrigerant, after complete compression, the electric motor 21 may also be cooled by refrigerant having an intermediate pressure.
For, example, the compressor is arranged such that the motor chamber 15 communicates with a first intermediate pressure chamber that is connected with the intake and exhaust ports of one of the cylinder bores, and a second intermediate pressure chamber that is connected with the intake and exhaust ports of the other one of the cylinder bores. That is, the motor chamber 15 has a pressure that is equal to half of those of the first and second intermediate chambers. The swash plate chamber 16 is connected with the first intermediate pressure chambers through the communication bore. That is, the motor chamber 15 has a pressure at a level intermediate the pressure level of the first and second intermediate pressure chamber. On the other hand, the swash plate chamber 16 is connected with the first intermediate pressure chamber through another communication bore different from a passage that is connected with the both intermediate pressure chambers and the motor chamber 15 .
In the compressor discussed above, since the intermediately pressurized refrigerant delivered to the first intermediate pressure chamber from the cylinder bore 13 A passes through the motor chamber 15 into the second intermediate pressure chamber and is drawn into the cylinder bore 13 B, the electric motor 21 is cooled. Further, since the intermediately pressurized refrigerant in the first intermediate pressure chamber is sent to the swash plate chamber 16 , the pressure of the swash plate chamber 16 is intermediate such that there is only a small pressure difference between the front and back ends of the pistons 26 , 27 .
In the illustrated embodiments, although compressors have been shown and described as having one pair of cylinder bores, the compressor may have more than one pair of cylinder bores. Also, the compressor may be single stage compressor, in which the refrigerant is compressed once and exhausted.
In the illustrated embodiments, although the compressors have been described as a fixed volume type compressors with a fixed stroke, the compressors may be variable volume type compressors with a variable stroke.
In the illustrated embodiments of the compressors of FIGS. 1 and 2 and FIGS. 5 and 6, the intake port 31 B is open at one end of the motor chamber 15 at a position opposite to the swash plate chamber 16 , however, the intake port may be formed in another area to meet various design changes in the compressor's structure or the motor chamber, provided that the motor chamber 15 and the swash plate chamber 16 are completely isolated in pressure from one another. Likewise, in the illustrated embodiment of FIGS. 5 and 6, the exhaust port 33 B may be formed in another area of the motor housing component 11 .
In the illustrated embodiments, further, although single intake ports 31 B and exhaust port 33 B are employed in the compressors, the motor housing component 11 may have plural intake ports 31 B and exhaust ports 33 B if desired. | A compressor includes a housing that has cylinder bores. A swash plate chamber communicates to the cylinder bores and a motor chamber partitioned from the swash plate chamber. A motor is disposed in the motor chamber actuates a drive mechanism in the swash plate chamber so as to move pistons in the cylinder bores. The refrigerant gas is supplied to an interior refrigerant passage of the compressor from an external refrigerant circuit. The swash plate chamber and the motor chamber are separated in the air tight manner. The motor chamber is connected to the interior refrigerant passage by a refrigerant path. | 5 |
RELATED APPLICATIONS AND CLAIM OF PRIORITY
[0001] This application is a continuation of U.S. patent application Ser. No. 11/056,429 filed Feb. 11, 2005, which is a continuation of U.S. patent application Ser. No. 10/081,260 filed Feb. 22, 2002, which is a continuation of U.S. patent application Ser. No. 09/593,531, filed Jun. 14, 2000, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/165,540 filed Nov. 15, 1999, the disclosures of which are incorporated herein by reference. It should be noted that U.S. patent application Ser. No. 09/592,928 filed Jun. 13, 2000, which issued as U.S. Pat. No. 6,347,095 also claimed the benefit of U.S. Provisional Patent Application Ser. No. 60/165,540.
FIELD OF THE INVENTION
[0002] The present invention relates to systems, devices and methods for providing services in a wireless environment based upon a user's proximity with respect to predefined spaces and the user's profile and also to methods of defining spaces, services and service group and the relationship between spaces and services, including the relationships between groupings of spaces and services.
BACKGROUND OF THE INVENTION
[0003] Low cost information access devices (such as cellular phones and handheld computers) are becoming ubiquitous. Moreover, traditional laptops and personal computers are quickly evolving to more readily operate in a wireless environment. As these devices are able to directly and indirectly interact with each other over short-range, wireless communications systems (using, for example, radio frequency energy), a new class of proximity-based applications and services will be enabled.
[0004] The present invention provides a system in which actions of the system are initiated or triggered based on the users' proximity to predefined spaces.
[0005] In another aspect, the present invention provides a system in which a service provider maps physical space into areas that are proximity enabled, specifies the relationship between these areas, and defines the services that are associated with these areas.
SUMMARY OF THE INVENTION
[0006] In one aspect, the present invention provides a system for delivery of services to at least one client program on a mobile device adapted to communicate in a wireless manner. The system includes:
[0007] a plurality of communication/detection devices, each of the communication/detection devices having a known range, each of the communication/detection devices being adapted to detect the presence of the mobile device when the mobile device is within the range thereof and to communicate information between the mobile device and the communication/detection device when the mobile device is within the range thereof, and
[0008] at least one multiplexer in communication with at least one of the communication/detection devices; and
[0009] at least one server including content stored thereon to provide at least one service to the client program on mobile device, the server being in communication with the multiplexer, the service to be provided to the mobile device depending on which one of the plurality of communication/detection devices is in communication with the mobile device.
[0010] Preferably, the multiplexer intermediates communication between the server and the communication/detection devices so that the client of the mobile device does not require information of the communication path to the server and the server does not require information of the communication path to the communication/detection devices.
[0011] In general, at least one service group including at least one service is mapped by the server to be available to a physical space defined by-at least one communication/detection device. An aggregate space can be defined by a set of at least two physical spaces. The server can also map at least one service group to be available to the aggregate space. Likewise, a higher level aggregate space can defined as a set of aggregate spaces, and the server can map at least one service group to be available to the higher level aggregate space.
[0012] The physical space is preferably defined by a plurality of communication/detection devices. The multiplexer preferably includes a software program to determine whether the mobile device is within the physical space from detection information provided to the multiplexer by the communication/detection devices. Multiple servers can be in communication with the multiplexer.
[0013] In another aspect, the present invention provides a method of providing services to a client program running on a wireless mobile device. The method includes the steps of:
[0014] defining a physical space by location therein of at least one communication/detection device having a known range, the communication/detection device being adapted to detect the presence of the mobile device when the mobile device is within the range thereof and to communicate information between the mobile device and the communication/detection device when the mobile device is within the range thereof, and
[0015] mapping at least one service group including at least one service to be available to client programs determined to be within the physical space. The service group can include a plurality of services.
[0016] The method can further include the steps of:
[0017] combining a plurality of physical spaces in a set to define an aggregate space; and
[0018] mapping a second service group including at least one service to be available to client programs determined to be present within the aggregate space.
[0019] Likewise, the method can also include the steps of:
[0020] combining a plurality of aggregate spaces in a set to define a higher level aggregate space; and
[0021] mapping a third service group including at least one service to be available to client programs determined to be present within the higher level aggregate space.
[0022] As discussed above, the physical space can be defined by multiple communication/detection devices. A software program preferably determines whether the mobile device is within the physical space from detection information provided to the software program by the communication/detection devices. In one embodiment, each of the physical spaces corresponds to departments within a place of business and the aggregate space corresponds to the entire place of business. Each of the physical spaces can also correspond to departments within a place of business, the aggregate space corresponds to the entire place of business, and the higher-level aggregate space corresponds to a plurality of places of business in a chain.
[0023] The present invention also provides a method of providing services to a client program running on a wireless mobile device including the steps of:
[0024] defining a physical space by location therein of a plurality of communication/detection devices having a known range, each communication/detection device being adapted to detect the presence of the mobile device when the mobile device is within the range thereof and to communicate information between the mobile device and the communication/detection device when the mobile device is present within the range thereof;
[0025] providing at least one server having at least one proximity-based application stored thereon, the proximity-base application being adapted to provide at least one service to be available to a client program stored on the mobile device when the mobile device is within the space, the service content being based upon higher level proximity-based events determined by periodic measurement of the presence or absence of the mobile device within the space; and
[0026] providing at least one intermediary, the intermediary being in communication with the plurality of communication/detection devices and in communication with the server, the intermediary including a program to determine if the mobile device is present within or absent from the space from detection information provided by the plurality of communication/detection devices, the intermediary adapted to transmit the information of whether the mobile device is present within or absent from the space to the server.
[0027] In one embodiment, the proximity-based events include an enter space event, a still within space event, a temporarily left space event, a returned to space event, and an exited space event.
[0028] The content addressed from the server to the client on the mobile device is preferably transmitted to the intermediary for storage thereon and transmitted to the client upon request by the client.
[0029] In still a further aspect, the present invention provides a method of providing services to a client program running on a wireless mobile device including the steps of:
[0030] providing at least one server having at least one proximity-based application stored thereon, the proximity-base application being adapted to provide at least one service to be available to a client program stored on the mobile device when the mobile device is determined to be within a set of spaces including at least one space, the service content being based upon higher level proximity-based events determined by periodic measurement of the presence or absence of the mobile device within the set of spaces;
[0031] determining whether the mobile device is present within each of the spaces in the set of spaces using a plurality of communication/detection devices having a known range, each communication/detection device being adapted to detect the presence of the mobile device when the mobile device is within the range thereof and to communicate information between the mobile device and the communication/detection device when the mobile device is present within the range thereof; and
[0032] providing the information of whether the mobile device is present within each space of the set of spaces to the server in a periodic manner to enable the server to determine the higher level proximity-based events.
[0033] The method preferably further includes the step of communicating content from the server to a client program on the mobile device via at least one of the communication/detection devices. Once again, the proximity-based events can include an enter space event, a still within space event, a temporarily left space event, a returned to space event, and an exited space event.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 illustrates a Bookstore and an adjacent Retail Store configured to support “proximity-based computing” in a mall.
[0035] FIG. 2 illustrates a model that specifies relationships between spaces, service groups, and services.
[0036] FIG. 3 illustrates a component and connector diagram for an embodiment of a proximity framework.
[0037] FIG. 3 . 1 illustrates the subcomponents of an embodiment of a multiplexer in an unconnected mass with respect to FIG. 3 .
[0038] FIG. 3 . 2 illustrates a partial object model of an embodiment of a multiplexer PRE.
[0039] FIG. 4 illustrates a state model of events for a detection mechanism.
[0040] FIG. 4 . 1 illustrates a state model of events for a simple space.
[0041] FIG. 4 . 2 illustrates a state model of events for an aggregate space.
[0042] FIG. 5 illustrates the subcomponents of an embodiment of a server in an unconnected mass with respect to FIG. 3 .
[0043] FIG. 5 . 1 illustrates a partial object model of an embodiment of a server Panlet Runtime Environment (PRE).
[0044] FIG. 5 . 2 illustrates a state model of events for a service.
[0045] FIG. 5 . 3 illustrates a state model of events for a Panlet instance.
[0046] FIG. 6 illustrates an embodiment of the concepts of spaces aggregation.
[0047] FIG. 6 . 1 illustrates the configuration of spaces and services in the Bookstore, which also contains a Caf.
[0048] FIG. 6 . 2 illustrates the configuration of spaces and services in the adjacent Retail Store.
[0049] FIG. 7 illustrates a particular instantiation of the model set forth in FIG. 2 , based on space and service group relationships specified in FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0050] Proximity-based computing gives a user's mobile device, whether it is a cell phone, personal digital assistant (PDA), laptop, or other device, the ability to be aware of the user's environment. Proximity-based computing preferably gives the user the ability to interact with nearby devices and objects without overwhelming the user by the complexity of his or her environment.
[0051] Two fundamentally different kinds of entities are envisioned to be found in a proximity-based environment: (1) mobile devices and (2) location-bound devices offering services. Mobile devices include, for example, cell phones, PDAs, laptops and other similar devices carried around by the owner. Location-bound devices represent the infrastructure needed by the content/services providers to deliver their content/services to mobile devices as they come within communication range of the location-bound device(s). A proximity-based environment is described generally in U.S. Pat. No. 6,347,095 entitled SYSTEMS, DEVICES AND METHODS FOR USE IN PROXIMITY-BASED NETWORKING.
[0052] I. System Overview
[0053] FIG. 1 illustrates a Bookstore and an adjacent Retail Store configured to support a “Proximity Computing” environment in a Mall. Components that might be found in such an environment include Clients, Servers, Multiplexers, Communication/Detection Devices, wired communication lines, wireless communication channels, walls and artificial constructs termed space(s).
A. Client A client C represents the software running on an end-user's mobile device (for example, a cell phone, a PDA, a laptop or a similar device). The client device is capable of wireless communication with other devices in its proximity. The software needed to allow the mobile device to interact intelligently with other devices in its proximity may, for example, include:
1. Device drivers that are used to permit wireless communication via a hardware transmitter/receiver (for example, the Bluetooth™. Technology for digital radio frequency communication of the Bluetooth™ Special Interest Group as set forth in the Bluetooth™ SIG 1.0 available from www.bluctooth.com. The Bluetooth™ specification specifies a system solution comprising hardware, software and interoperability requirements and operates in a common 2.4 GHz ISM band.) 2. Low-level proximity aware services that are also used to establish and maintain wireless communication links (referred to herein as “proximity services”). 3. Proximity runtime environment (PRE) software is responsible, for example, for retrieving service-related content, shielding the user from unwanted content, determining how much of a user's preferences to expose to its environment, etc. 4. A portal application that allows a user to interact with proximity-based services. The portal application can, for example, be a Graphics User Interface (GUI)-based interface (where sufficient screen real estate is available). The user interface can also be based on other media using, for example, touch or sound. It is through the portal application that users navigate among the various proximity-based services available in a given setting.
B. Communication/Detection Device A communication/detection device is illustrated in FIG. 1 as a solid black circle with the label “C/D”. It represents a proximity-based, location-bound device that is used to detect client devices as they enter its detection range and to forward this information to interested parties.
[0063] Communication/detection devices C/D are also used to facilitate two-way communication between a client device and a service wishing to offer content to any mobile devices in that communication/detection device's physical proximity. For example, a device C/D is used to detect mobile devices as they come into proximity and to then set up a higher level connection for example, (an IP-based connection) that allows a client to interact “directly” with a multiplexer (MUX) described in detail below. This higher-level communication will, for example, be relayed through device C/D's short-range wireless device (for example, a Bluetooth™ radio) to bridge the gap between the multiplexer, which may not be capable of wireless communication, and the mobile client, which is generally capable of only wireless communication (that is, the mobile client is cable free). Communication between the devices C/D and a multiplexer may, for example, be via a typical local area network or LAN. A communication/detection device C/D preferably runs a version of proximity services very similar to the version of proximity services running on the client.
C. Multiplexer A multiplexer (MUX) is illustrated in FIG. 1 and serves as an intermediary between clients, communication/detection devices C/D and servers. A MUX preferably allows communication among such entities while shielding them from each other's details and complexity. Such an arrangement has certain benefits from the perspectives of both clients and servers. Benefit of such an arrangement include, but are not limited to the following:
1. Clients do not have to know how many servers are offering content in any given area or the location of the server(s). Servers can, for example, be “on location” (for example, in the Bookstore or in the Mall) and connect to multiplexers via a local area network or be off location and connect to multiplexers via a wide area network (WAN) or a global network such as the Internet. From the point of view of a client, a multiplexer presents a single point of interaction over which services are offered in a physical space. Whether one server or many servers are used to offer the services that a client sees is irrelevant to the client. 2. Clients do not have to know which services are available via which servers. All mapping is handled by the multiplexer. Content can be retrieved from the multiplexer without being concerned with the data path required to get that content from a server. 3. Servers do not have to know details about the type of communication/detection devices available in an area (this information is managed by multiplexers). Instead, servers have to know only that communication and detection services are available in an area. 4. In cases in which a client can be contacted via multiple communication/detection devices, the multiplexer can determine which path is optimal given current bandwidth restrictions. The possibility of alternative paths need not be known to the server. For example, in an area that has a high volume of client use and a large number of clients present, the same physical space may be served via multiple communication/detection devices simply to have enough active channels to handle the number of clients. In this case, the multiplexer determines which clients are contacted via which communication/detection devices. A multiplexer is configured by a person familiar with the physical environment, a space maintainer. A space maintainer has two primary groups of responsibilities. First, a space maintainer has logical knowledge of the layout of physical spaces. For example, the client (located between Fiction and History spaces in the Bookstore of FIG. 1 ) who has no immediate contact with nearby communication/detection devices will be counted by a multiplexer as being present inside the Bookstore even though the client's presence can't be detected via any communication/detection devices. Further, in the case of FIG. 1 , the multiplexer can consider a client to be still present in the Bookstore unless the last communication/detection device reporting detection of the client was the device positioned near the Entrance space (the only way to exit the Bookstore). Second, a space maintainer can group a set of communication/detection devices to serve a single space such that services can be directly provided to that space. A multiplexer may also be responsible for tying together the knowledge established about a client via multiple communication/detection devices into a single, coherent picture. This aggregation of communication/detection devices representing the same space is known as a detection mechanism. The multiplexer thus preferably has some understanding of spaces, how spaces are related to communication/detection devices, and where clients are in relation to spaces. A multiplexer also serves as an indirection provider. Given the bandwidth restrictions on the logical link between clients and a multiplexer, it is preferable that the multiplexer not push new content across to clients simply whenever such content is available. Particularly in cases in which the client may not access content for a given service, or may not even open the portal application. As such, a multiplexer preferably queues content from services until the content is requested by the client for which it is destined. Once content is delivered to a client, it is preferably removed from the queue in the multiplexer. Additionally, content is preferably staged as close (in terms of latency before getting the information) as possible to the client. Communication/detection devices are poor choices for such staging as they are likely limited in terms of available resources. Servers are potentially a few network hops away. This leaves the multiplexer as a reasonable place to stage content.
D. Server A server is a host for a number of services. Preferably, servers shield the services as much as possible from having to about the topology of the various types of connections that are required to provide content from a service to clients. In addition to the services residing on the server, the server will contain a proximity runtime environment (PRE) that manages the proximate world as seen by the server. The server PRE preferably:
1. Manages its world view from the perspective of what services are available on the server and how they relate to the spaces. It also preferably determines how much of this world view to expose to clients as it becomes aware of them. 2. Determines which services should be informed of new clients upon detected activity. 3. Determines to which multiplexer to route service content in cases in which alternate paths via multiple multiplexers are possible.
E. Proximity Framework The proximity-enabled world can, for example, be explained in terms of three basic concepts: spaces, services and service groups. FIG. 2 illustrates a “world view” model that specifies relationships between spaces, service groups, and services.
1. Space A space is an abstraction of a physical area in the real world. Spaces preferably come in two varieties: simple spaces and aggregate spaces. Simple spaces are associated directly with a specific physical area, and typically correspond to a continuous area. Simple spaces may overlap each other. In contrast, an aggregate space is defined in terms of a set of child spaces that may be geographically separated or continuous. Examples of simple spaces include a department in a retail store, a conference room at a hotel, or the area around a sculpture exhibit at a museum. Two examples of aggregate spaces are a chain of department stores and a department store composed of the simple spaces corresponding to the different departments in the store. The services available to a user are a function of the spaces that the user is currently occupying. 2. Service A service is an application that provides proximity-triggered content targeted to particular locations. The content available to a user will change as the user enters and exits spaces, and based on the user's movement within spaces. For example, a customer may receive an electronic greeting summarizing the day's discounts when entering a department store, or be asked if the client would like to speak with a sales person if the client spends an extended period of time in front of one display. 3. Service Group A service group is a set of related services or service groups. Services groups provide a way for organizations to package services that will very likely be targeted to the same set of locations or to the same sorts of clients. For example, an airline might define two separate service groups so that it can provide one set of services to its typical customers, and an augmented set to its “frequent flyers.” A particular service may be included as part of more than one service group. Service groups may be part of other service groups as well.
[0086] FIG. 3 illustrates a component and connector diagram for the proximity framework. This diagram illustrates primarily software components and how the software components interact at a high level of abstraction.
[0087] Most components' definitions and functionalities were discussed in connection with FIG. 1 and FIG. 2 . The connectors set forth in FIG. 3 can be described as follows:
[0088] Device Discovery: A device discovery connector deals with the low level discovery and/or communication protocols used by communication/detection devices to detect client devices. As clear to one skilled in the art, such low level discovery and communication protocols can vary with communication/detection technology.
[0089] Client Detection: A client detection connector deals with how a multiplexer is made aware of clients as they are detected.
[0090] Content from Server: Content from server connector is primarily concerned with getting service generated content from a server to the multiplexer. Content from server refers generally to pages of information generated by services that are tied to one of, for example, five proximity events (described below) and to a specific service. This type of page is understood by the proximity framework, and is delivered to clients as described herein. Each page of service-generated content is preferably generated for a specific client, allowing services to tailor content to clients. The five proximity events are events that are triggered by the proximity framework and have proximity specific meaning. The five proximity events are the following:
A. Enter: This event indicates that a client has entered an area in which services are available, and those services should be informed that they may now offer content to the client. B. Still Here: This event indicates that a client is still present in an area in which services are available. It merely indicates that the client has not left, and serves as a heartbeat of sorts that allows additional content to be offered over time as a client remains in an area. C. Leave: This event indicates that a client has left an area in which services are available, but that the client could still comeback. That is, it hasn't been gone so long that it is inconceivable that the client device's user could simply step back into range. D. Comeback: This event indicates that a client device has returned to an area of service that it had recently left (Leave). E. Exit: This event indicates that the client is considered to have been gone from an area of service for such a period of time that it can be deemed not to be coming back anytime soon.
[0096] Content to Client: Content to client connector is primarily concerned with getting service-generated content that is staged at a multiplexer to a client when the client is ready for it.
[0097] External Content Delivery: External content delivery connector is used to get external content to clients on request. It may also be used to allow clients to provide information to services by means of filling out a form sent back to the service residing on the server (by means of the server being the external entity in this case). External content refers to pages of information that are not tied to the five Proximity events, but that may be accessible via links in the pages tied to the five Proximity events.
[0098] II. Multiplexer Architecture
[0099] In this embodiment, a gateway sub-component encompasses everything else in the server component. The gateway sub-component is preferably responsible for all interactions over the Client Detection connector, Content from Server connector and Content to Client connector. Further, it routes all external content communications between Client and external context sources.
[0100] FIG. 3 . 1 illustrates the sub-components of the multiplexer of FIG. 3 unconnected from the other components of FIG. 3 (that is, in an unconnected mass), with the multiplexer's use of connectors refined to show which sub-component uses each connector. The contents and purpose of each sub-component are summarized below:
A. Gateway The gateway is used to relay requests for external content to, for example, the Internet. One skilled in the art will appreciate that gateway component protocol is not limited to WAP. For example, the gateway component protocol can be http etc. B. Multiplexer Panlet Runtime Environment (PRE) The Multiplexer PRE preferably facilitates communication between clients and services that is proximity specific. Things such as knowledge of world views (that is, a specific instance or instantiation of relationships between spaces, services and service groups), understanding of the semantics of content associated with the five proximity events, mappings between communication/detection devices and detection mechanisms (that is, a group of communication/detection devices defining a single simple space), and mappings of detection mechanisms to spaces are managed therein. The multiplexer PRE is generally significantly different from the PRE's running on either clients or servers.
[0105] A significant amount of information preferably can be managed by the multiplexer. Examples of data retained in are summarized as follows:
1. Knowledge of all simple spaces managed by the multiplexer and which detection mechanisms cover each simple space. 2. Knowledge of how multiple communication/detection devices are mapped to detection mechanisms. 3. Knowledge of any aggregate spaces and which other aggregate spaces and simple spaces are included in aggregate spaces. 4. Knowledge of which servers are interested in which spaces.
5. Knowledge of what each server intends to do with client data, should it receive client data (that is, a client profiles/server intentions model). 6. Knowledge of which clients (if any) are currently present in each space.
7. Knowledge of which services are currently available to each client currently present in at least one space (i.e., the accumulated world view for each client). 8. Knowledge of what pages of service-generated content are available for each client.
[0114] FIG. 3 . 2 illustrates an object model depicting part of the Multiplexer PRE. The object model is focused on the relationship between communication/detection devices and detection mechanisms, the mapping of detection mechanisms to simple spaces, and the relationships among spaces.
[0115] The communication/detection devices are preferably not mapped directly to simple spaces. Instead, only detection mechanisms are preferably mapped to simple spaces. A primary reason for this is to allow multiple communication/detection devices to be aggregated into a single detection mechanism, which serves a simple space. There are two primary benefits for this type of mapping. First, one may want to collect different types of data from different types of communication/detection devices (for example, infrared and Bluetooth™) that cover the same physical area into a single detection mechanism. This would result in a more knowledgeable source of information (likely using different technologies) that presents a single representation or point of interaction for that physical area. Second, one may want to group multiple similar communication/detection devices to present a single interface to a larger physical space than any single communication/detection device could cover. By hiding the multiple communication/detection devices behind a single detection mechanism, one does not permit services to be bound to any of the smaller areas covered by a single communication and detection device.
[0116] Communication/detection devices are preferably not part of a multiplexer. Preferably, there is a proxy of the communication/detection device in a multiplexer.
[0117] Detection mechanisms are mapped directly (one-to-one) with a simple space. Aggregate spaces can then be composed from other spaces, simple or aggregate. This mapping permits a site administrator (someone who can configure the multiplexer managing all the communication and detection devices in an area) to present different kinds of spaces for different needs. This can, for example, mean grouping adjacently located simple spaces into aggregate spaces that represent a larger, contiguous area, or it can mean grouping related simple spaces into an aggregate space that represents all areas with similar interests. It is an arbitrary grouping mechanism for which exact uses are generally tied to needs.
[0118] Both types of spaces, simple and aggregate, are considered locations to which services can be tied or addressed. Preferably, locations are visible to servers, not communication/detection devices and detection mechanisms. The multiplexer, therefore, preferably ensures that all clients that are detected by a communication/detection device must result in the appropriate services on servers being notified of the client detection. To do this (which is somewhat complicated by the different kinds of grouping managed by the multiplexer) the multiplexer must propagate detection notices from entity to entity in this model, performing the appropriate filtering along the way so that a service won't be informed multiple times when a client device enters locations in which the service offers content. That is, a service only wants to be informed if it should offer a client content, not that a client is within two or more overlapping sub-locations of a location in which the service is offering content.
D. Proximity Event Propagation Proximity event propagation in FIG. 4 illustrates the manner in which a detection mechanism handles notifications from the communication/detection devices that it represents for the case that communication/detection devices form a perfect proximity detection coverage over the simple space. If none of its communication/detection devices can detect a client, then there is no client detectable by the detection mechanism. If at least one of its communication/detection devices can detect a client, then that client is detectable by the detection mechanism. Whenever a detection mechanism first detects or can first no longer detect a client, it will inform the simple space with which it is associated. In cases where the actual deployment of communication/detection device(s) does not form a perfect proximity detection coverage over a simple space, the state model of events for a detection mechanism should adapt to best accommodate the situation. All the state models presented represent the state that is maintained with respect to a single client. In reality, the state a communication and detection device can be thought of as the state of all clients as detected by the communication/detection device. The state of the communication/detection device is thus represented by an arbitrary number of parallel state machines, each of which is generally as illustrated in FIG. 4 .
[0121] The propagation continues in FIG. 4 . 1 with an illustration of how simple spaces can deal with client detection. It is an even simpler model than set forth in FIG. 4 , since a simple space can only be associated with one detection mechanism. Whenever a detection mechanism detects a client, so does the simple space. The same applies for lack of detection. Upon detection or lack of detection, a simple space preferably informs any aggregate spaces that are parent spaces. It also preferably informs any servers that have expressed an interest in that location.
[0122] While propagation to a server can occur via a simple space, it can also occur via an aggregate space. FIG. 4 . 2 shows how an aggregate space can handle detection and lack of detection. Its model is very similar to that of a detection mechanism. Like the detection mechanism, an aggregate space can be composed of an arbitrary number of sub-spaces. As such, detection of a client by an aggregate space equates to whether or not any of the sub-elements can detect the client.
[0123] III. Server Architecture
[0124] FIG. 5 shows the sub-components of a server component and the general arrangement of those subcomponents. Further, the server's use of connectors is refined to show which sub-component uses each connector. The contents and purpose of each sub-component in this embodiment are summarized below:
A. Server In this embodiment, a third party server sub-component encompasses everything else in the server component. The third party server sub-component is preferably responsible for all interactions over the Content from Server connector, and routes all incoming communications to the server PRE. A server preferably provides an additional benefit to proximity-based applications, and serves as their only means of getting feedback from clients. If a proximity-based application wants to request information from a client, it can, for example, provide a form for the client user to complete. This information can then be sent back to the proximity-base application by means of the External Content Delivery connector. B. Server PRE The server PRE encompasses a lot of intelligence in terms of keeping services aware of changes in client presence (that is, as clients move in and out of spaces), and using client preferences to determine whether or not to make services aware of a client. The server PRE is also preferably responsible for informing multiplexers of the server's intentions for use of client preferences/profiles, which can be compiled based upon the intentions of the services hosted on the server. Additionally the server PRE preferably generates world view information that is tailored for specific clients and sends this information to the appropriate multiplexer(s). The server PRE is preferably the primary source of stimulation for proximity-based applications. It can keep track of the state of clients with respect to any relevant proximity-base applications (services) in terms of the five proximity events set forth above. The server PRE preferably informs the proximity-based application of any state changes. Each event given to a proximity-based application will give the proximity-based application an opportunity to respond with new content to be offered to the client. There is also a possibility that the server PRE can cache content that services are generating, for example, to support a scenario in which the same service can route content to the same client via different multiplexers. This scenario requires the client to be in two different, but overlapping spaces that happen to be managed by different multiplexers, both of which the same server is using to offer content. C. Proximity-Based Applications A server typically hosts a number of proximity-based applications. Each proximity-based application is preferably an implementation of a service to be offered to proximity-based clients. Each proximity-based application preferably has a prescribed interface for interacting with the server PRE. Each proximity-based application can also have other interfaces to allow access to non-proximity specific information (e.g., a hotel's registration database). FIG. 5 . 1 illustrates an object model depicting part of an embodiment of a Server PRE and focuses on the relationship between services and the locations in which those services are offered. These concepts are discussed below and used to explain how the data necessary to generate the five proximity events gets from a multiplexer to a service. In this embodiment, there are two different kinds of addressable locations (those locations at which a service can be targeted): location (proxies) and aggregate locations. A location (proxy) is a representation of a location that is available via a multiplexer. An aggregate location is some collection that groups location (proxies) from different multiplexers. It is not meant as a general purpose grouping mechanism to group location (proxies) from the same multiplexer in arbitrary fashions. There is a one-to-one mapping between each service and the proximity-based application instance implementing the service. The service object is distinct, as there may be some state maintained on a per service basis. Services can be grouped into service groups, groups of services to be deployed to the same addressable location. Service groups can also be part of other service groups. Either services or service groups can be offered to addressable locations. D. Proximity Event Propagation The proximity event propagation starts with how events are received from a multiplexer. In this embodiment, the events are received at a location (proxy), that being the interface to a multiplexer from the Server PRE perspective. This event is passed on to all entities interested in the events of this location that can be an aggregate location, a deployable service, or both. Aggregate locations collect events from all addressable locations of which they are composed and form a new view. In general, if, and only if, a client is present in any addressable location within that aggregate location, it is also present in the aggregate location (a state model is not shown for this step). Aggregate locations likewise propagate events from their composed perspective to all entities interested in events of this location. Either way, an event indicating that a client has been detected in some addressable location will be received by a deployable service. If this deployable service is a service, its actions are shown in FIG. 5 . 2 . The received-events, Client Detected and Client Not Detected, are the only events that a service will receive. The service preferably transforms this information, together with accumulated state and timing parameters (.DELTA.t and timeout), into the five proximity events that are forwarded from a service to the proximity-based application instance it is representing. The .DELTA.t parameter represents how often the service informs the proximity-based application instance that the client is still present. It serves as a heartbeat of sorts and can serve as an opportunity for a proximity-based application instance to generate new content for a client (that is, the proximity-based application instance is permitted to generate content only in response to receiving one of the five events from a service). If the deployable service is a service group, it preferably simply forwards any received events to all services and service groups that make up the service group. In reality, since each service or service group can be targeted to an arbitrary number of addressable locations, each needs to have a more complicated state model that collects events from a number of different sources and forms a new, composite state.
EXAMPLE
[0141] FIG. 6 illustrates the concepts of space(s) aggregation in an environment specified by FIG. 1 , and it includes a variety of services that are mapped to corresponding spaces. Further, FIG. 6 is sub-divided into FIG. 6 . 1 and FIG. 6 . 2 . FIG. 6 . 1 illustrates the configuration of spaces and services in the Bookstore, which also contains a Caf. FIG. 6 . 2 illustrates the configuration of spaces and services in the adjacent Retail Store.
[0142] To provide services that are available to a customer anywhere in a particular Bookstore, one first creates a space corresponding to the entire store (see FIG. 6 ).
[0143] To cover the entire Bookstore, one creates an aggregate space, “Bookstore, Anywhere, USA,” that contains all three Bookstore spaces: fiction, history and the caf. Collectively, these spaces define the aggregate space. When a customer is present within any one of these simple spaces, he is considered to be within the “Bookstore, Anywhere, USA” aggregate space, and all of the services targeted to the “Bookstore, Anywhere, USA” aggregate space will be available to him.
[0144] It would be ideal if the physical area covered by the three simple spaces in Bookstore corresponded perfectly to the area contained by the Bookstore, the history space corresponded perfectly with the history section, and the three spaces were distinct and non-overlapping. However, because of the limitations of detection technologies like Bluetooth™, it's very likely that in reality either these spaces will overlap at the edges, or there will be regions in the store that are not covered by a simple space. In general, spaces will be an approximation of a physical area. In practice, this means that it is possible that a customer standing on the threshold between the fiction section and the caf will have access to sets of services that are offered in either space.
[0145] In this Example, the Bookstore provides storewide services including a calendar of events a local card catalog that lists all the items currently in stock and their locations within the store. These are packaged as the “Bookstore Services” group and targeted to the “Bookstore, Anywhere, USA” aggregate space.
[0146] If one wanted to provide services that were specific to a particular area of the Bookstore one can target the services directly to the child (simple) spaces. For example, a menu could be targeted specifically to the Bookstore caf.
[0147] To target services to all of the Bookstore locations across the country, one can define a larger aggregate space corresponding to the entire Bookstore chain. In this example, services available to all stores within the Bookstore chain are packaged in the “Bookstore Standard Services” service group, which itself is composed of two service groups, “Information” and “Promotions”.
[0148] By defining spaces to represent both the local Bookstore as well as the entire chain of Bookstores, one enables both location-specific services as well as services that are to be available across locations.
[0149] For the adjacent Retail Store (for example, a tie store) there may be no need for location-specific services. In this case the only services available are those tied to the aggregate space corresponding to all Retail Store outlets across the country.
[0150] The Bookstore Caf may actually be affiliated with two retailers—the Bookstore that houses the caf, as well as, for example, a national Caf chain. The Caf chain may also want to deliver services to its customers at this location. For example, the Caf chain may have a service to send coupons for free coffee to frequent customers For the Caf chain to provide its own services to the caf, one preferably creates an aggregate space that includes all of the Caf chain's locations. Once the space is created, the Caf chain can make services available to its locations across the country by associating service groups with the space.
[0151] The mall itself may want to offer services that are available throughout the mall. In this case, one can define an aggregate space composed of all locations within the mall, including the local Bookstore space (an aggregate itself) and the Retail Store space.
[0152] In the previous sections, all of the described services were provided by a retailer (e.g., Bookstore), or the owner of the physical area housing the retailer (e.g., the Mall). A space can also be used to host services provided by some third party. For example, stores like the Bookstore and the adjacent Retail Store can contract with a company (National Promotions) that brokers coupons, advertisements, and promotions for companies with complementary products. For a fee, the advertising broker National Promotions can target its services to these retailers' locations—either their entire chains or individual stores. In FIG. 6 , the advertising broker is shown to target its services to the aggregate spaces representing the retailers' chains.
[0153] FIG. 7 illustrates a particular instantiation of the model set forth in FIG. 2 , based on space and service group relationships specified in FIG. 6 . The targeting of a service group to a space is shown with an arrow, while the hierarchy of spaces is shown with undecorated lines. For example, a user standing in the “Caf” space (see FIG. 1 ) is also considered to be present within the “Bookstore (Anywhere, USA)” space, “Bookstore”, “Caf Chain” and “The Mall”. All of the services targeted to these spaces may also be available to the user (see FIG. 6 ).
[0154] Assuming that a user is interested in all possible services available at a location, and the user is authorized to interact with all of them, the following services will be available within the caf space:
[0155] Bookstore Standard Services
[0156] Information
[0157] N.Y. Times Bestsellers
[0158] Featured Authors
[0159] Promotions
[0160] Store Sales
[0161] Frequent Customer Coupons
[0162] Caf Services
[0163] Frequent Customer Program
[0164] Bookstore Services
[0165] Calendar of Events
[0166] Card Catalog
[0167] Mall Services
[0168] Mall Map
[0169] Personal Shopper
[0170] National Promotions
[0171] Coupons
[0172] Advertisements
[0173] Promotions
[0174] A user might not, however, see all of the services targeted to a location. Services may be not be available because:
[0175] The user has specified that he is not interested in particular services or classes of services.
[0176] The user is not authorized to use the service (for example, he or she hasn't purchased a service option, does not have an account with the company offering the service, or hasn't met some other qualifying criteria).
[0177] The user was not included in the user group targeted by the service (e.g., certain promotions may be directed at a particular demographic).
[0178] Moreover, the way in which services are actually displayed to the user may also vary. Depending on the user's preferences and how services are classified, they may be displayed in a particular way.
[0179] Although the present invention has been described in detail in connection with the above examples, it is to be understood that such detail is solely for that purpose and that variations can be made by those skilled in the art without departing from the spirit of the invention except as it may be limited by the following claims. | A system is provided for delivery of services to at least one mobile device adapted to communicate in a wireless manner including a plurality of communication/detection devices. Each of the communication/detection devices is adapted to detect the presence of the mobile device when the mobile device is within the range thereof. Each communication/detection device is adapted to communicate information between the mobile device and the communication/detection device when the mobile device is within the range thereof. The system includes at least one multiplexer in communication with at least one of the communication/detection devices and at least one server including content stored thereon to provide at least one service to the client program on mobile device. The server is in communication with the multiplexer. The service to be provided to the mobile device depends on which one of the plurality of communication/detection devices is in communication with the mobile device. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to well bore cleaning assemblies and more particularly to clean out assemblies for cleaning well casing perforations by water pressure.
2. Description of the Prior Art
In my prior U.S. Pat. No. 4,892,145, issued on Jan. 9, 1990, I have described a new, mechanical, clean out tool for opening well perforations in a well casing. This tool is particularly useful in fracturing solid debris collected and blocking the casing perforation.
In the course of pumping well fluids from any ground formation silt, sand, and other particulate matter migrate to the well bore and then deposit at the perforations in the casing. Eventually this accumulation closes off the flow and the well becomes unproductive. Thus periodic cleanout is necessary and, depending on the form and chemistry of the accumulate, this cleanout may require mechanical or water flow mechanisms, or both.
One mechanical arrangement has been referred to above and reference is therefore invited to the teaching of my prior U.S. Patent for the manner of operation of such a device. Water based cleanout devices in the prior art typically take the form of a manifolded mandrel tied to the end of a hollow rod string through which water, at pressure, is conveyed into the well bore. To confine this water pressure to the mandrel length, an upper and lower resilient thimble seal are provided.
These prior devices, while suitable for the purposes intended, occasionally hang up and are opposed in their passage by offset partings in the casing, occasional collapse in the casing walls, or bends or dog legs in the bore.
Thus a water cleaning assembly that passes these occasional defects is extensively sought and it is one such assembly that is disclosed herein.
SUMMARY OF THE INVENTION
Accordingly, it is the general purpose and object of the present invention to provide a water bearing well cleaning assembly conformed for passage across casing irregularities.
Other objects of the invention are to provide a water based well cleaning assembly which collapses in its geometry for insertion an removal.
Yet further objects of the invention are to provide a collapsible water flow confinement structure useful for cleaning a well bore.
Briefly these and other objects are accomplished within the present invention by conforming a generally cylindrical mandrel into an upper and lower mandrel segment, the upper segment terminating in a fitting for threaded attachment to the end of a hollow rod string. Each segment, moreover, at the distal ends, forms a seal against which a mating annulus of a cup shaped thimble seal is engaged. The upper segment, along the axial direction down from its seat, forms a generally cylindrical structure expanding into a set of radial projections to oppose the upward progression of the lower cup seal. The lower mandrel segment is generally conical in shape threaded or otherwise attached by its apex to the underside of the upper segment. At its base the lower segment forms the other seal for the annulus of the lower cup seal.
Thus both the upper and lower cup seal are free to move along the axis of the mandrel one displaced from their respective seats. When displaced onto the mandrel the upper cup seal allows for some lateral motion within the limits of the annulus. The lower cup seal, similarly, will allow for lateral motion between the lower mandrel segment and its annulus, which is progressively greater as the cup moves up along the cone. In this manner substantial irregularities in the well casing are accommodated, by lateral displacement of the seals, allowing the insertion and removal of the tool.
Both the upper and lower cup seals may be formed from an elastomeric material, the upper cup being inverted while the lower cup is aligned to present its cavity upwards. Preferably, each cup seal is somewhat smaller in diameter than the nominal inner diameter of the well casing, with sufficient edge compliance to expand, by water pressure, against the casing walls.
The mandrel may be mainifolded along two separate flow paths, one to convey the pressurized water stream through the rod string into the upper segment and thence radially out, and the second for transferring well fluids between a set of ports in the upper tapered seat to an opening at the lower end of the mandrel. Thus, when the upper cup seal is unseated well fluid is free to transfer across the tool, and once the seals are seated the rod string flow, at pressure, is confined between the seals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, in partial section of a prior art water based well cleaning assembly;
FIG. 2 is yet another side view, in partial section, of the inventive water pressure well cleaning assembly, in the course of passage down a well bore;
FIG. 3 is the side view shown in FIG. 2 with the inventive assembly deployed for cleaning; and
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Well bore cleaners have had extensive use and development in the past. In typical configuration such prior art cleaning assemblies take the form illustrated in FIG. 1 and reference thereto is now taken for the functional description of thereof. More precisely such prior art cleaning assemblies, generally indicated at 10, attach to the lower and of a tube string TS which at the surface S may be tied to a source of pressurized water PW to convey this flow of pressurized water against the walls of the well casing WC. A substantially cylindrical mandrel 11 forms the center manifold therefor, the mandrel being generally circular in section, of a radial dimension substantially smaller than the radial dimension of the well. This first manifold comprises an inlet opening 12 threaded to the end of the tube string TS which then communicates into an axial path 13 running partly into the mandrel. A plurality of radial drillings 14, extending through the mandrel to the axial bore, then direct the water flow at the casing walls.
Of course, this flow of pressurized water is most effective when confined. Accordingly, an upper and a lower resilient cup seal, 21 and 22 respectively, are mounted on the upper and lower ends of the mandrel. Each of the seals 21 and 22 comprises a generally dished resilient fitting 21a and 22a mounted on an annular ring 21b and 22b. Ring 21b corresponding, in turn, engages a tapered seats 18 formed at the upper end of the mandrel. The upper seat 18, furthermore, includes an array of inlet ports 25 which communicate through a separate mainifold 26 into the lower end fitting 17 of the mandrel. This fitting may then be threaded to other downhole devices that may be combined for effective cleaning.
In common practice the upper portion of the mandrel 11 is cut to a reduced section 18a adjacent the seat 18, thus allowing for axial translation of the seal 21 away from its seat. Thus any substantial upward movement of the assembly 10 will displace seal 21 from its seat, allowing the well water to equalize through ports 25 and the associated manifold 26.
The lower seal 22 is generally fixed in place, with the inward flexure of the edges of the seal providing pressure relief from below, and thus permits the descent of the tool into the well bore.
In this general form the prior art cleaning assembly 10 provides a confinement for the fluid at pressure, sent down the pipe string. Specifically, seals 21 and 22 are expanded, by the cleaning pressure, against the well walls, this confined fluid pressure is then useful to backwash and open any debris collected at the well perforations WP.
While extremely effective, the foregoing assembly lacks the convenience of passage across irregular ties in the well casing. Thus the seal edges occasionally catch and bind at parting offsets in the basin, at doglegs or bends in the bore, or at inward collapses in the casing walls.
Illustrated in FIGS. 2-4 is my inventive cleaning assembly which resolves each of the foregoing problems. More precisely, as shown in these figures, the inventive cleaning assembly generally designated by the numeral 50, comprises a mandrel assembly 51 including an upper segment 52 and a lower segment 53. The upper segment 52, at its upper distal, end forms into a threaded female fitting 521 conformed to mate with the lower end of the tube string TS. Right below the fitting, mandrel segment 52 tapers down in section to form a tapered seat 522, below which a reduced mandrel section 523 is formed, similar to the reduced section 18a in the prior art assemblies.
An annular seal assembly 71 is coaxially mounted on the reduced section 523. Seal assembly 71 is characterised by an annular steel base or collar 711 onto which a resiliant cup seal 712 is fixed. Collar 711, moreover, includes a mating seat surface 713 to seal against the seat 522. Thus seal assembly 71 is free to move from its seating engagement onto the length of the reduced section 523, allowing for both vertical and lateral offset once thus translated.
Below the reduced section 523 the mandrel segment 52 expands to a larger cylinder 528 terminating at its lower end in a set of radial fins or tabs 529. The lower segment 53, in turn, is shaped as a frustoconical structure defined by a cone frustrum 531 attached by its apex to the lower end of segment 52 and terminating in a sealing cylinder 532 at the bottom. Cylinder 532 is provided with a pair of sealing grooves in which sealing rings 534 & 535 are mounted. An enlarged fitting 538 is then formed on the end of the mandrel.
The lower seal assembly 72 comprises a tubular hollow collar 721 from which yet another resilient cup seal 722 extends. The interior dimension of collar 721 conforms for sealing fit against the sealing rings 534 and 535 but is opposed from further downward descent by the structure of fitting 538. Thus seal assembly 72 is free to migrate upwardly onto the reduced conical surface of the frustrum 53, being limited in the upward translation by the fins 529. As it migrates upwardly, progressively larger lateral offsets become possible, accomodating various surface irregularities in the well walls. This then, accomodates convenient tool passage past casing offsets, bulges, or doglegs.
Once brought to the desired well depth, water, at pressure, may be introduced through the tube string TS into fitting 521 and thence through a central drilling 631 in segment 52 into a set of radial ports 641 therein. In a manner similar to the device 10 a secondary, equalization, manifold 761 is also formed in segment 52 ported at ports 751 adjacent the sealing surface 522.
In this manner a water cleaning assembly is provided which accomodates surface irregularities in a well casing.
Obviously many modifications and changes may be made to the foregoing description without departing from the spirit of the invention. It is therefore intended that the scope of the invention be determined solely on the claims appended hereto. | A water pressure cleaning assembly useful in cleaning out the perforations in a well casing includes a mandrel structure defined by an upper cylindrical segment and a lower conical segment. An upper and lower annular seal is movable respectively along the upper and lower segments to allow relative motion of the mandrel structure within the annuli thereof. This lateral motion then allows the passage of the assembly across irregularities in the casing. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to powder metallurgy and more particulary to the consolidation of metal powders into hollow, cored, and composite shaped parts of nearly solid metals.
Hundreds of thousands of straight tubular fittings made of the Nitinol class of shape change alloys have been used in pressurized and unpressurized pipe and tubing systems in ships and aircraft. These fittings can be connected without expensive welding procedures. However, straight tubular fittings make up only a small fraction of the tubular fittings in these systems. Considerably greater savings can be realized if the more complex fittings, such as tees, ells, crosses, and wyes, can be economically made of the Nitinol alloys.
Unfortunately, these complex fittings can not be cast from Nitinol alloys and machining such shapes from solid Nitinol metal alloy is prohibitively expensive. Nor can state of the art powder metallurgy techniques be used to produce these complex fittings from the Nitinol alloys. The "hot isostatic pressing" (HIP) process requires that the alloy powder be sealed in expensive welded metal cans of the desired shape and placed in special, very expensive chambers capable of applying high temperature and pressure at the same time. Even for simple forms this is an extremely expensive procedure. Another common procedure is called the CIP-sinter process in which the alloy powders are compacted at ambient temperature and then vacuum sintered. This procedure is unsuitable for producing complex fittings of sufficient density.
U.S. Pat. No. 4,227,927 which issued to Herbert L. Block and Jerome Schwertz on Oct. 14, 1980, discloses the CAP® process, "consolidation by atmosphere presure". In this process the metal powder is enclosed within an evacuated glass container, which is then embedded within a free flowing refractory powder, such as graphite, and heated within an air atmosphere furnace. This process, however, has been limited to producing solid objects such as in the tool industry. In order to produce pipes and other hollow objects double walled glass molds would be required. Such molds for complex fittings such as tees, crosses, wyes, etc., would require highly skilled glass blowers and would be prohibitively expensive.
It therefore would be desirable to provide a relatively inexpensive process for producing complex-shaped fittings of Nitinol alloys which have high density and strength.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to provide a new powder metallurgy process.
Another object of this invention is to provide a powder metallurgy process for producing complex-shaped Nitinol alloy pipe and tubing fittings.
A further object of this invention is to provide a method of producing high density, high strength, Nitinol alloy pipe and tube fittings.
Yet another object of this invention is to provide a low cost method of producing Nitinol alloy complex-shaped pipe and tubing fittings.
A still further object of this invention is to provide a method of producing hollow Nitinol alloy objects.
These and other objects of this invention are accomplished providing a method of producing a hollow complex fitting from metal and metal alloy powders by loading the powders into a mold having a solid graphite core corresponding to the desired shape and dimensions of the interior of the fitting and an outer wall of a glass which becomes plastic at the sintering temperature, the outer glass wall corresponding to the outer shape of the fitting to be produced. The mold is evacuated, sealed, and packed along with a free flowing refractory powder into an open refractory container and heated at sintering temperature until the metal or alloy has been consolidated as indicated by the outer glass wall ceasing to shrink. The mold is cooled to room temperature during which the outer glass wall breaks away from the consolidated metal and alloy. The solid graphite core is removed by machining to produce the metal or alloy fitting. If the graphite core is left in, the composite object may be used as a structural element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a mold structure for producing a straight fitting;
FIG. 2 shows the resulting straight fitting before the graphite core has been removed;
FIG. 3 shows a mold structure for producing a tee fitting;
FIG. 4 shows a mold structure for producing a cross fitting;
FIG. 5 shows a mold structure for producing an elbow fitting; and
FIG. 6 shows a mold structure for producing a wye fitting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the mold structure for producing a simple, straight Nitinol alloy fitting according to the process of this invention. A graphite core 10 defines the shape and dimension of the interior of the final fitting. A glass outer wall 12 in the shape of the outer wall of the final Nitinol fitting completes a sealed annular container. The glass outer wall 12 becomes plastic when heated during the sintering step. The space 14 between the graphite core 10 and glass outer wall 12 is filled with powdered Nitinol alloy. Initially a hole is present in the glass wall 12 to allow the loading of the alloy powder into the space 14. The atmosphere in the space 14 is then removed under vacuum and the hole in the glass wall 12 is sealed. The evacuation may be accompanied by mild heating to remove occulded gases from the alloy powder.
The alloy powder is next consolidated using the CAP® process as disclosed in U.S. Pat. No. 4,227,927, entitled "Powder Metallurgy," which issued to Herbert L. Black et al. on Oct. 14, 1980, herein incorporated by reference. Black et al. (in claim 1, col. 4, lines 19-31) summarize the next steps to be taken as follows:
"(d) placing the mold in an open top refractory container and packing with free flowing refractory powder selected to freely flow at all the temperatures encountered in the process, (e) heating the mold and contents of the mold to a temperature at which sintering of the powder metal takes place and holding at this temperature for a time sufficient to cause substantially complete densification of the powder metal, (f) cooling and removing the mold to recover a dense article, and whereby the glass mold is supported by the free flowing refractory powder as the mold becomes plastic and shrinks in volume as its contents densify."
For greater density a modification of the CAP® process may be used. This procedure is disclosed in U.S. Pat. No. 4,564,501, entitled "Applying Pressure While Article Cools," which issued on Jan. 14, 1986, to David Goldstein, herein incorporated by reference. Goldstein (col. 3, lines 16-29) summarizes this modification to the CAP® process as follows:
"Another application of this slow cooling under pressure modification is to obtain greater density in the nickel-titanium alloys objects than can be obtained by the unmodified CAP® process. The conventional CAP® process is used up to the cooling step. The clay-graphite container (including refractory powder, glass molds, nickel-titanium alloy object) is transferred directly to an insulated container which is placed in a pressure chamber. The insulated container is not air tight so that that pressure in the chamber will be felt on the glass molds. A pressure of 15,000 psi or more, preferably 40,000 psi or more, and more preferably from 100,000 to 200,000 psi is applied during cooling. In this manner, a high density product is achievable without hot working."
After the consolidation step, the mold and consolidated alloy material are cooled to room temperature. During the cooling, the glass breaks away leaving the consolidated alloy pipe 16 and the graphite core 10 as shown in FIG. 2. This composite piece might be used as a structural member. Usually, however, the graphite core is machined out to produce a hollow
This method is useful in the production of more complex fixtures such as tees, crosses, elbows, and wyes(Y'S). FIG. 3 shows the mold structure for producing a tee with graphite pieces 18 and 20 connected at joint 24 to produce the graphite core 10 which is centered and positioned within the glass wall structure 12 by positioning and centering bosses 28. The space 14 between the graphite core 10 and glass wall 12 is packed with the alloy powder, evacuated, and sealed in.
FIG. 4 shows the mold structure for producing a cross with graphite pieces 18, 20, and 22 connected at joints 24 to form the graphite core 10 which is centered and positioned within the outer glass wall structure 12 by positioning and centering bosses 28. The space 14 between the graphite core 10 and the glass wall 12 is packed with the alloy powder, evacuated, and sealed in.
FIG. 5 shows the mold structure for producing an elbow with graphite pieces 18 and 20 connected at joint 24 to produce graphite core 10 which is centered and positioned within the outer glass wall structure 12 by positioning bosses 28. In this case graphite cement is used to connect graphite pieces 18 and 20 together at joint 24. The space 14 between the graphite core 10 and the glass wall 12 is packed with the alloy powder, evacuated, and sealed in.
FIG. 6 shows a mold structure use to produce a typical wye with graphite pieces 18 and 20 connected at joint 24 to product graphite core 10 which is centered and positioned within the outer glass wall structure 12 by positioning bosses 28. The space 14 between the graphite core 10 and the glass wall 12 is packed with alloy powder, evacuated, and sealed in.
In the final product, the shape and dimensions of the hollow interior of the fitting are those of the graphite core 10 used. Although the graphite cores shown in FIGS. 1-6 are made up of cylindrical shapes, other more complex and even irregular-shaped graphite cores may be used. The Nitinol alloys are very hard and extremely difficult to machine. In contrast, the graphite is soft and easy to remove. As a result, a wide range of techniques such as scraping or abrading may be used in addition to conventional techniques such as drilling to remove the graphite.
The shape of the external surface of fitting will be the same as the shape of the glass wall structure 12. Although the glass walls shown in FIGS. 1 and 3-6 are cylindrical or made up of cylindrical shapes, other more complex and even irregular shapes may be used.
The thicknesses of the metal walls 16 of the final fixture will be determined by the initial packing density of the alloy powders, the final density of the alloy structure after the consolidation process, and the initial space 14 between the walls of the glass structure 12 and the graphite core 10. By varying and adjusting these factors, the desired size and shape of fitting may be produced.
Examples of alloys for which the method of the present invention is useful include the shape memory alloys of nickel and titanium (NITINOL). Fittings made of these alloys are useful in providing weldless connections for pressurized and unpressurized liquid and gas systems. However, as these Nitinol alloys are not castable and are extremely difficult to machine, the present method is very valuable.
Specific examples of Nitinol alloys which may be used in the present method to produce fittings include those containing from 38 to 47, and preferably from 42 to 46 weight percent of titanium, from zero to about 6 weight percent of an additive metal which is cobalt, iron, or mixtures thereof, with the remainder of the alloy being nickel. When the additive metal is omitted (zero weight percent) the alloy is binary (Ti-Ni). As is well known in the art, from more than zero to about 6 weight percent of additive metal (Co, Fe, or mixtures thereof) may be added to change the transition temperature range (TTR) of the shape memory alloy. Small amounts (up to a few percent) of other elements may be added to these alloys provided that they do not interfere with the shape memory effect.
The density of the consolidated alloy material in the fittings must be at least 95.5 percent of the theoretical density. Higher densities are preferred and may be necessary in certain applications such as in high pressure gas systems. A number of factors affect the density of Nitinol fittings produced by the method of this invention. Finer alloy powder will result in a denser product. Alloy powders of -60 mesh are preferred, with -100 mesh being more preferred. A practical limitation on the alloy powder size is cost; for example, -300 mesh Nitinol powders are extremely expensive and therefore not practical for this process. A common technique for increasing density in powder metallurgy is to mix small particles in with the larger particles; the small particles fill in holes left between the large particles. Finally, it should be noted while the CAP® process of U.S. Pat. No. 4,227,927 is suitable for many of the applications of the method of the present invention, the modified process of U.S. Pat. No. 4,564,501 produces denser products. This is particularly true when very high pressures are applied during the slow cooling step.
Obviously many modifications and variations of this invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | Alloy powder is packed into a mold which comprises a complex-shaped solid aphite inner core and a similarly complex-shaped thin glass outer wall. The mold is evacuated, sealed, and then heated to the alloy sintering temperature, the glass softens and applies an isostatic pressure on the alloy as the alloy particles consolidate. After the consolidation step, the mold and its contents are cooled and the glass and graphite materials are removed from the alloy object. This method is particularly useful for preparing complex fittings of Nitinol shape memory alloys. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Non-provisional Patent Application of U.S. Provisional Patent Application No. 61/036,588, entitled “Training Nozzle/Tip for Welding Applications”, filed Mar. 14, 2008, which is herein incorporated by reference.
BACKGROUND
[0002] The invention relates generally to welding guns, and more particularly to positioning attachments for controlling torch angle and/or torch to workpiece height during welding.
[0003] Welding is a process that has increasingly become ubiquitous in all industries. While such processes may be automated in certain contexts, a large number of applications continue to exist for manual welding operations, the success of which relies heavily on the proper use of a welding gun or torch. For instance, an improper torch angle can lead to a spatter, improper penetration, and overall poor weldments. However, inexperienced welders often have difficulty establishing the proper torch angle and torch to workpiece distance during welding, and such skills may be somewhat difficult to teach. Furthermore, even experienced welders may have difficulty maintaining these important parameters throughout welding processes.
[0004] Certain gas nozzles have been proposed that are used to establish the proper torch to workpiece distance during spot welding. However, these nozzles are less than satisfactory in addressing the overall problem, in particular because they do not establish the proper torch angle, are limited in scope to spot welding applications, and do not teach proper technique. Therefore, there exists a need for a device that will aid welders or welding trainees in establishing the proper torch angle and torch to workpiece distance.
BRIEF DESCRIPTION
[0005] The present invention provides a device designed to respond to such needs. The invention may be used in conjunction with a variety of welding guns as well as for multiple types of welding. It may be used solely for training purposes or during routine welding operations as well. In particular, the invention provides a positioning attachment for guidance of torch angle and/or torch to workpiece distance. The positioning attachment may contain one or more legs of equal or different lengths, that may be capped with a tip, and that contact the workpiece. The leg or legs extend from a body, which may be permanently attached or removably secured to the welding torch nozzle, or any other component of the welding torch. Certain embodiments may be made of heat resistant metals or ceramic to withstand high temperatures during welding.
DRAWINGS
[0006] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0007] FIG. 1 is a perspective view of a welding torch with a positioning attachment;
[0008] FIG. 2 is a side elevation view of a weld and a welding nozzle with a positioning attachment;
[0009] FIG. 3 is a top perspective view of a welding nozzle with a positioning attachment;
[0010] FIG. 4 is a further view of the add-on attachment and the welding nozzle;
[0011] FIG. 5 is a side elevation view of a three-legged positioning attachment;
[0012] FIG. 6 is a side elevation view of the positioning attachment in a welding position;
[0013] FIG. 7 is a front elevation view of a positioning attachment with two equal length legs;
[0014] FIG. 8 is a front elevation view of a positioning attachment with two slightly unequal length legs;
[0015] FIG. 9 is a front elevation view of a positioning attachment with two unequal length legs;
[0016] FIG. 10 is a front elevation view of a leg of the positioning attachment and a tip;
[0017] FIG. 11 is a side elevation view of a welding nozzle with a contact tip extension;
[0018] FIG. 12 is a side elevation view of a welding nozzle with an angled contact tip extension;
[0019] FIG. 13 is a perspective view of a further embodiment including 4 legs or prongs of unequal length; and
[0020] FIG. 14 is a perspective view of another embodiment having 4 legs.
DETAILED DESCRIPTION
[0021] FIG. 1 illustrates a welding torch 10 that incorporates a positioning attachment 12 , which establishes the proper torch angle and/or torch to workpiece height during welding or welding training. The torch 10 has a handle 14 with a trigger 16 , which a welder may use to start and stop welding. An extension 18 from the handle 14 is connected to a nozzle 20 . A contact tip 22 extends outward from the inner cavity of the nozzle 20 . One embodiment of the present invention, which includes two positioning legs 24 , 26 permanently attached to the outside of the nozzle on either side of the aperture 28 , is shown in FIG. 1 . During welding, wire is fed out of the contact tip 22 while gas is fed out of the aperture 28 into the welding area. In certain embodiments, the positioning attachment 12 may be made of a metal, such as brass or steel, which is resistant to the heat generated during welding. In other embodiments, the positioning attachment 12 may be made of ceramic. It should be noted that, although the embodiments illustrated in the figures relate generally to metal inert gas (MIG) welding arrangements, the invention may be adaptable to other systems and technologies, such as tungsten inert gas (TIG) torches.
[0022] FIG. 2 illustrates one embodiment of the present invention in which the positioning attachment 12 is permanently secured to the welding gun nozzle 20 . In this embodiment, one positioning leg 24 may be longer than the second positioning leg 26 so that the gun can be precisely positioned during the weld 30 . In the illustration of FIG. 2 , for example, the weld 30 is progressing in a right to left direction 32 . The positioning attachment 12 ensures that a proper torch to weld height 34 and torch angle 36 are maintained as welding proceeds in the indicated direction 32 . FIG. 3 illustrates a top perspective view of this weld process. The first positioning leg 24 is located in front of the weld as the nozzle 20 moves in the indicated direction 32 .
[0023] FIG. 4 illustrates one possible embodiment of the present invention. In this embodiment, an add-on attachment 38 is the means for removably securing the positioning attachment 12 to the nozzle 20 . The body 40 of the add-on attachment 38 is positioned around the nozzle 20 while the inner surface 42 of the add-on attachment 38 fits onto the tip of the nozzle 20 . In this embodiment, the positioning attachment 12 is removably secured to the nozzle 20 , enabling easy replacement and mobility between torches.
[0024] FIG. 5 illustrates a three leg positioning attachment 44 . In this embodiment of the present invention, two opposed positioning legs 46 , 48 are of equal length and are perpendicular to the body 40 of the positioning attachment 12 . The third rear leg 50 is a different length and connects to the body 40 at an angle. The three positioning legs 46 , 48 , 50 establish a fixed torch angle and torch to work piece height. In certain embodiments, the three leg positioning attachment 44 is made of a heat resistant metal while in other embodiments it may be made of ceramic. FIG. 6 illustrates a side elevation view of the three leg positioning attachment 44 connected to the welding nozzle 20 during welding. The opposed leg 46 and the rear leg 50 define the proper torch angle 52 as the welding torch is moved along the workpiece. It should also be noted that, where desired, the legs may all be of different lengths, and the one leg may follow along the center of the intended weld, or may be displaced to the side of the intended weld location. Additionally, in further embodiments, the positioning attachment 44 may have more than three legs, which establish the proper torch angle and/or torch to workpiece height during welding or welding training.
[0025] FIG. 7 is an illustration of a side elevation view of a level positioning attachment 54 in which the positioning legs are the same length. In this embodiment, the torch angle 56 is set to zero (i.e., generally perpendicular to the workpiece), and the torch to workpiece height is fixed 58 . In another embodiment, the positioning legs are of unequal lengths, and an angled attachment 60 is formed as shown in FIG. 8 . The unequal leg lengths create a torch angle 62 , which is greater than that of the level positioning attachment 54 , and a fixed torch to workpiece height 64 . In a similar embodiment, an angled attachment 66 has positioning legs that are of more unequal lengths, leading to an even greater torch angle 68 and a fixed torch to workpiece length 70 . In other embodiments, the lengths of the positioning legs may be any combination of intermediates between the shown illustrations.
[0026] FIG. 10 illustrates the positioning leg end 72 and a tip 74 , which securely fit together in the assembled positioning attachment 12 . In certain embodiments, the positioning tip 74 may be made of a heat resistant metal or ceramic such that it may interface with (e.g., contact) the workpiece in an area of intense heat from the weld. The removability of the tip 74 allows for easy replacement should it wear or degrade over time.
[0027] FIG. 11 is an illustration of one embodiment of the present invention in which the positioning attachment 12 takes the form of a special contact tip extension 76 . This extension 76 extends inside the nozzle 20 . This embodiment could either be used solely for training purposes, that is, for illustration of the correct torch angle and torch to workpiece length, or for welding as well as training if the extension 76 is made of a material sufficiently resistant to the temperatures present during welding. FIG. 12 shows another adaptation of this embodiment where the contact tip extension 78 is angled. The extension 78 still extends into the nozzle 20 and defines the proper torch angle and/or torch to workpiece distance.
[0028] FIG. 13 illustrates a further embodiment in which the torch attachment includes 4 legs. As in the previous embodiments, the attachment includes a body 80 that may be configured for snapping onto or otherwise fitting to an end (e.g., a nozzle) of a welding torch. This embodiment, however, includes a front leg 82 , two side legs 84 and 86 , and a rear leg 88 . The lengths of the legs are selected to properly orient a torch to which the device would be attached. In this embodiment, for example, the front leg 82 is longer than the rear leg 88 , causing the torch to be leaned downwardly during welding, with the front leg riding along a line where a weld is to be formed, and the rear leg riding over a progressing weld. The two side legs are shorter than both the front and the rear legs, and may contact workpieces on either side of a progressing weld. This embodiment may be particularly well suited to welds formed between workpieces joined at an angle.
[0029] FIG. 14 illustrates another embodiment of the attachment with 4 legs. In this embodiment, a body 90 has a front leg 92 extending from it, with two intermediate legs 94 and 96 somewhat shorter than the front leg, and a read leg 98 somewhat shorter still. The attachment will cause the torch to be leaned downwardly with the front leg again riding along a line where a weld is to be formed, and the rear leg riding over a progressing weld. The side legs will then ride along sides of the weld. This embodiment may be well suited for welds formed between abutted workpieces (e.g., plates).
[0030] In both embodiments with 4 legs, the lengths of the legs may be selected to provide the proper height of the torch about the weld location, and the proper angle of the torch with respect to the workpiece or workpieces. The side legs, for example, may be the same or different lengths to provide for a particular orientation of the torch. Similarly, other arrangements may be envisioned in which the legs are intended to straddle the weld rather than to ride along an intended weld line or a recently formed weld.
[0031] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A positioning attachment for definition of torch angle and torch to workpiece distance during welding and/or training is provided. The positioning attachment includes one or more legs of equal or varied lengths capped with a tip, which contacts the workpiece, and a body, which may be permanently attached or removably secured to the welding torch nozzle. Certain embodiments may be made of heat resistant metals or ceramic to withstand high temperatures during welding. The positioning attachment may be mounted on the welding torch nozzle or provided as an extension of the contact tip. | 1 |
TECHNICAL FIELD
The present invention relates generally to flow control devices and more particularly to flow control devices for use in heat pump systems for air conditioning units and the like.
BACKGROUND OF THE INVENTION
It is known in the prior art to provide a flow control device such as a piston in a conduit such that when coolant flows in a forward direction, the device engages and meters the flow of the coolant. When the piston is disengaged, flow of the coolant is reversed and flow is in an unrestricted manner.
When flow control devices are positioned within a conduit and are further positioned to move in a predetermined manner with respect thereto, flow conditions often result in high fluid velocities in the areas close to or adjacent to the device. Consequently, operational noise associated with the flow and turbulence of the fluid as it moves in relation to the device is thereby produced. Operational noises traditionally tend to be rattles, vibrations and the like. Additionally, the fundamentals of fluid mechanics teach that the forces developed by moving fluids result in noise and turbulent flow near the device. This is in part attributable to the unequal distribution of noise levels passing over the piston or flow control device.
Attempts to reduce noise level associated with flow control devices have been of limited success. For example, U.S. Pat. No. 4,896,696 to Bradley, et al discloses a flow control restrictor. However, there is still a need in the art for a flow control device which further reduces operational noise and eliminates other disadvantages associated with the prior art such as difficulties with respect to sizing, fit, sticking, cocking and failure to seat correctly.
It would therefore be desirable to provide a flow control device which controls the rate of flow in one direction, provides unrestricted flow in the reverse direction and which eliminates the shortcomings associated with the prior art.
BRIEF SUMMARY OF THE INVENTION
The present invention overcomes the foregoing and other problems with an improved flow control piston having a specific configuration on the outer surface thereof to distribute and direct the flow of coolant or fluid. The flow control device in accordance with the present invention has the advantage of a shaped elongated body which equally distributes the flow across the surface of the piston. In an alternative embodiment of the invention, the nose of the piston has a greater angle or is sharper than devices of the prior art to reduce drag and improve stability of the piston. One of the advantages of the device in accordance with the present invention is that flow control, including the equal distribution of flow, is improved in both the regulated and the unregulated flow positions. The equal distribution of flow greatly enhances the stability of the piston. Consequently, noise levels influenced by fluid passing over the device is reduced. Although not required, another embodiment of the present invention may include a channel in the device such that a gasket may be positioned therein.
In preferred embodiments of the invention, an elongated body of the device has a square configuration such that four flows about the body are provided. In a more preferred embodiment of the invention, the device has a hexagon configuration and thus includes six flows about the body. Additional embodiments may also include elongated bodies having a rectangular or pentagonal shape. Additionally, these embodiments may also include a nose portion which is not as blunt as the noses of devices known in the art. This provides the further advantage of reducing cocking, thereby allowing for increased guidance for seating and enhanced stability. In this manner, noise levels due to rattle and vibrations are minimized by equally dividing the flow and turbulence waves within the system.
The foregoing has outlined some of the more pertinent aspects of the present invention. These aspects should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention as will be described. Accordingly, other aspects and a fuller understanding of the invention may be had by referring to the following Detailed Description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference should be made to the following Detailed Description taken in connection with the accompanying drawings in which:
FIG. 1 is a partial cross-sectional side view of a first embodiment of the present invention;
FIG. 2 is a side view of a second embodiment of the present invention;
FIG. 3 is a cross-sectional view illustrating the flow control device of the present invention positioned in a conduit of a heat pump system; and
FIGS. 4A through 4D are cross-sectional end views of conduits containing a flow control device of the present invention illustrating the flow channels formed therein.
DETAILED DESCRIPTION
Referring now to the drawings and more particularly to FIG. 1, there is illustrated a partial cross-sectional, side view of a first embodiment of the present invention. The flow control piston 10 includes a nose region 12 on an elongated body 14. The nose region 12 consists of a nose cone 16 shaped like a truncated cone. The truncated portion of the nose cone 16 forms the leading edge 18 of the flow control piston 10. The nose cone 16 also includes a channel 20 for receiving a gasket providing sealing characteristic for the piston 10 when the piston is in the regulated flow position which will be more fully discussed in a moment. The piston 10 will seat on a gasket or the nose cone 16 when the piston 10 is in the regulated flow position.
The elongated body 14 comprises a hexagonally-shaped surface 24. When fluid flow passes over the piston 10 the hexagonally-shaped surface 24 provides six lines of contact, one along each face of the hexagonal surface 24 such that the volume of fluid flow past the piston 10 is substantially split into six equal flow distributions. This equal distribution of fluid flow about the piston 10 improves the seating and stability of the piston during nonregulated fluid flow. Additionally, the noise levels associated with fluid passing over the piston 10 are greatly reduced due to the equal divisions of fluid flow over the surface of the piston. While FIG. 1 is described with respect to the elongated body 14 having a hexagonal surface 24, the present invention functions equally well when a square surface is used in place of the hexagonal surface, rectangular or pentagonal on the elongated body 14.
The rear portion of the elongated body 14 also could include a conical surface 26 acting as a fin to control the effects of turbulent flow over the hexagonal surface 24. A bore 30 passes through the interior of the piston 10 along the longitudinal axis of the piston to enable flow in both the regulated and unregulated flow directions.
Referring now to FIG. 2, there is illustrated an alternative embodiment of the present invention for a flow control piston 40. In this embodiment, the piston 40 again comprises a nose region 42 connected by a trailing edge to an elongated body 44. The nose region 42 includes a nose cone 46 shaped as a truncated cone wherein the truncated portion of the cone form the leading edge 48 of the nose cone 46. The surface of the nose cone 46 is steeply angled to substantially reduce the drag forces of fluid flow in the direction indicated generally by arrow 50. The steeply angled surface of the nose cone 46 greatly reduces the energy and forces acting on the piston 40 and substantially reduces rattling and vibrations by the piston. The piston 40 will seat on the nose cone 46 when the piston is in the regulated flow condition.
Elongated body 44 comprises a hexagonal surface 56. As described previously with respect to FIG. 1, the hexagonal surface 56 provides six lines of contact along each of the hexagonal surfaces which substantially split the volume of fluid flow into equal distributions along each face of the hexagonal surface 56. This reduces the rattle and vibrations of the piston 40 caused by the fluid flow. A rear fin 58 on the trailing edge of the elongated body 44 could be utilized to control the turbulent flow of fluids past the hexagonal surface 56. A bore 60 along the longitudinal axis of piston 40 enables the passage of fluid flow through the interior of the piston.
While the piston 40 of FIG. 2 has been described generally wherein the elongated body 44 has a hexagonal surface 56, it should also be noted that the elongated body 44 may also have a square, rectangular or pentagonal surface. In the case of a square or rectangular surface, four lines of contact are created (one along each surface) to equally divide the fluid flow past the piston 40 to reduce rattle and vibrations within the piston 40 created by the fluid flow. In the case of a pentagonal surface, five lines of contact are created.
Referring now the FIG. 3, there is illustrated the previously described second embodiment of the present invention installed within a conduit of a heat pump system 66. The heat pump system 66 includes conduits 68, 70, and 72 interconnected with one another by fittings 74 and 76 which are threadedly engaged with each other. Fittings 74 and 76 include a chamber 78 enabling a fluid, typically a coolant, to flow between the conduits. Fluid flows in the direction of arrow 82 when the flow is regulated and in the direction of arrow 80 when the flow is unregulated.
The piston 40 of FIG. 2 is slidably mounted in the axial direction within the chamber 78. When fluid flows in the direction of arrow 80, the piston 40 moves in the direction of arrow 80 until the piston engages fitting 76 providing fluid flow at an unregulated rate. The angled nose cone and multiple lines of contact provided by the hexagonal or square surface of the elongated body 44 greatly reduce the rattling or vibration of the piston 40 when the piston is positioned in this location. When the direction of fluid flow is reversed to the direction of arrow 82, piston 40 disengages fitting 76, moves axially in the direction of arrow 82 and engages fitting 74. Flow in this direction is regulated. While the description of FIG. 3 has been made with respect to the embodiment disclosed in FIG. 2, any of the embodiments or modifications previously disclosed would be utilized within a conduit in a similar manner.
Referring now to FIGS. 4A through 4D, there are illustrated end views of conduits containing hexagonal, rectangular, square and pentagonal pistons 84 in accordance with the present invention. As can be seen from the figures, the shaped pistons 84 each create a plurality of substantially equally sized passages 86 for directing the fluid flow around the piston. These passages 86 will split the volume of fluid flow into substantially equal distributions passing around each surface (or line of contact) of the piston. The equally distributed fluid flows and the aerodynamically-shaped nose cone of the piston, greatly reduce rattling and vibrations within the piston caused by fluid flow over the piston.
It should be appreciated by those skilled in the art that the specific embodiments disclosed above may be readily utilized as a basis for modifying or designing other structures for carrying out the purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. | A fluid flow control device for use in heat pump systems is provided. The device includes an elongated body shaped to define a plurality of lines of contact along the elongated body which reduces operational noise and which improves fluid flow characteristics. In a preferred embodiment, the device includes four or six lines of contact. The device may also include a highly angled nose region to improve seating and stability. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application 60/721,973 filed on Sep. 30, 2005.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not Applicable.
FIELD OF THE INVENTION
[0003] The present invention relates to a heating appliance, and in particular, to a heated press for fusing plastic materials such as plastic beads.
DISCUSSION OF RELATED ART
[0004] Many children enjoy crafts and hobbies that allow them to form artistic or useful shapes from plastic. These types of hobbies are beneficial to young children as the hobbies are opportunities for the child to practice attention to detail, to develop manual dexterity, and to express creativity.
[0005] One such hobby is the making of artistic shapes by fusing plastic beads. Bead fusing uses small cylindrically shaped beads. The beads are available in a wide range of colors and sizes. To produce a shape or object, the beads are placed in a mold with pegs for holding the beads. The cylindrically shaped beads are slid over the pegs in the mold. The hobbyist selects the colors of beads appropriate for his or her design and chooses the peg for each bead in order to create the desired design. To finish the project, the bead tops are fused. Fusing uses a heat source to melt the tops of the beads together to fuse the beads into the desired pattern. Conventionally, a clothing iron is used as the heat source for melting the beads. The tops of the beads are covered with a thin, non-stick material so that the melted beads do not adhere to the surface of the iron. A typical material used to protect the iron is a wax-coated paper.
[0006] After the tops of the beads are fused and the beads have cooled, the project can be removed from the mold. Many hobbyists repeat the fusing process on the back of their projects to make the finished product sturdier.
[0007] A first concern associated with the practice of bead fusing by small children is the risk of burn injuries. A type of bead typically fused has a melting temperature of approximately 200° F.-220° F. Children four years of age and older enjoy bead fusing. Younger children in particular may not appreciate the hazard associated with the high temperatures, placing them at risk of receiving burns when handling the hot iron or when handling heated beads. As a result, adults must closely supervise children when they are fusing beads. For very young children, adults must perform the fusing operation for the child. When an adult performs the fusing for the child, the child misses out on some of the enjoyment and benefits of participating in the hobby. It would be beneficial if young children could safely apply the fusing heat source themselves without exposure to a risk of receiving a burn injury.
[0008] A second concern is controlling the relevant process variables to achieve a reliable fusing of the bead tops. When the beads are excessively melted, the appearance of the bead project is degraded, while incompletely fused bead projects are similarly unattractive and less sturdy than a properly fused project. The important variables to control during fusing are the temperature of the iron and the duration of the application of iron's heat to the beads. Unfortunately, the temperature controls on irons are only roughly calibrated. Generally, irons do not indicate a temperature setting in degrees, but rather display temperature adjustment ranges labeled like “cotton” or “permanent press,” indicating the types of fabric to be ironed at that setting. Because the fabric settings are not standardized, there can be wide variation in temperature of an iron adjusted to the “cotton” setting. It would be advantageous if the temperature of the heat source were reliably adjusted to a known value so that ideal fusing of beads may be reliably accomplished.
[0009] Several devices have been developed for heating and shaping plastic materials. German Patent No. 3,919,164, published Dec. 13, 1990, describes a device with a movable upper plate that presses against the contour of plastic materials to weld or cut the materials. German Patent No. 3,938,380, published May 23, 1991, describes an apparatus with a movable press plate and a non-stick slip film for extruding plastic material. German Patent No. 19,858,152, published Jun. 21, 2000, describes an apparatus for the production of plastic boards, including a press with heated and cooled sections for stretching plastic materials. Japanese Patent No. 57-155,255, published Sep. 25, 1982, describes a press-molding apparatus for producing a molded article from thermosetting resin containing glass beads.
[0010] None of the above inventions and patents describes the present invention as claimed. Thus, a press for fusing beads solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0011] The press for fusing beads heats the tops of beads to fuse the beads together, fixing them in a pattern. The press preferably includes a control circuit that ensures a consistent, repeatable heating cycle used in the fusing process, and that operates the press to achieve an enhanced degree of safety for a user. The press includes an enclosure having an open slot at the front face. A heating plate having a heating element is mounted within the enclosure. A tray, which holds the beads to be fused, is placed on a tray support that slides within the open slot to a position under the heating plate. A control circuit senses the position of the tray support, and when the tray is in position beneath the heating plate, allows an operator to initiate a timed heating cycle. When the heating cycle is initiated, the control circuit either activates an actuator within the enclosure to move the tray upward, placing the tops of the beads into contact with the heating plate, and energizes the heating element to heat the heating plate to a predetermined temperature; or the user uses a manual vertical actuator mechanism to lower the heating element onto the beads in the tray manually.
[0012] At the completion of the heating cycle, the heating element is de-energized, and the control circuit either controls the positioning actuator to lower the tray back upon the tray support, or indicates to the user that the melting cycle is complete and that the user should raise the heating element back into its elevated position.
[0013] The press may provide a number of additional actuators and sensors to detect conditions associated with the press and to control the operation of the press. The press may include a fan in electrical connection with the control circuit. The control circuit operates the fan to cool beads and the internal components of the press at the end of a heating cycle. An electrically operated latch for holding the tray support plate within the press may be provided, or a locking post on the lowerable heating assembly may mechanically engage a locking post receiving means of the tray to prevent the tray from being slid out of the slot of the enclosure. The latch is electrically connected to the control circuit, which operates the latch to prevent the tray from being removed from the press during and after the heating cycle, while the beads are still hot. The press may be provided with indicator lights and a display that provide information to the user concerning the state of operation of the press, allowing the user to understand when it is safe to start the press and when to remove the bead tray from the press. The display can further provide an indication of abnormal or potentially unsafe conditions monitored by sensors within the enclosure.
[0014] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1A is a perspective view of a press for fusing beads according to the present invention as seen from the front.
[0016] FIG. 1B is a perspective view of the press of FIG. 1A as seen from the rear.
[0017] FIG. 1C is a perspective view of the press of FIG. 1A as seen from the bottom.
[0018] FIG. 2 is a perspective view of a press for fusing beads according to the present invention, broken away and partially in section to show details of the tray holder assembly.
[0019] FIG. 3 is a perspective view of a press for fusing beads according to the present invention, broken away and partially in section to show details of the heating element assembly.
[0020] FIG. 4 is a block diagram of a computer-based safety control circuit for the press of the present invention.
[0021] FIG. 5 is a process diagram showing operations implemented by the safety control circuit of FIG. 4 .
[0022] FIG. 6 is a top plan view of the preferred embodiment of the invention, illustrating a tray support plate in an extend position.
[0023] FIG. 7A is a left-side elevational view of the preferred embodiment of the invention, partially broken away, illustrating the tray support plate in the extended position.
[0024] FIG. 7B is a left-side elevational view of the preferred embodiment of the invention, partially broken away, illustrating the tray support plate, and a tray thereon, under a heating plate of the present invention.
[0025] FIG. 7C is a left-side elevational view of the preferred embodiment of the invention, partially broken away, illustrating the heating plate in a lowered position and in contact with beads on the tray.
[0026] FIG. 7D is a left-side elevational view of the preferred embodiment of the invention, partially broken away, illustrating a scraper being introduced into a second slot of invention, the scraper dislodging fused beads from the heating plate.
[0027] FIG. 8 is a perspective illustration of the preferred embodiment of the invention. Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] The present invention is a press for fusing beads, designated generally as 20 in the drawings. As shown in FIGS. 1A, 1B , and 1 C, the press is shown to include an enclosure 21 with user interface components 230 on the exterior of the enclosure 21 . The user interface components 230 may include an alphanumeric display 40 , indicator lights 44 , 46 , 48 , and a start button 42 . A control circuit 200 , described below, controls the operation of the press 20 , sensing the pressing of the start button 42 to start a bead fusing cycle and indicating, via the indicating lights 44 , 46 , and 48 and the alphanumeric display 40 , the operating state of the press 20 . The control circuit 200 also monitors sensors 224 within the press 20 to detect conditions that might potentially result in unsafe operation.
[0029] Electrical power for controlling and operating the press 20 is provided via an electrical power cord 50 terminating in an electrical plug 52 . The plug 52 is adapted for connection to a source of electrical power from a conventional AC receptacle, such as 110V AC in North America and 220V AC in Europe, for example.
[0030] The press 20 further comprises a tray support plate 94 . The tray support plate 94 slidably engages a tray guide 30 so that the tray support plate 94 can be slid within the enclosure 21 of the press 20 . The drawer guide 119 ( FIG. 7A ) may be further included to support the tray support plate 94 between its extended and retracted positions. A handle or knob 26 attached to the front of the tray support plate 94 provides a purchase that allows a user to slide the tray support plate 94 in or out of the press 20 . The upper surface of the tray support plate 94 is adapted to hold a tray 22 . A recessed area 24 of the tray 22 is adapted to hold a bead mold 17 containing beads 25 to be fused by the press 20 .
[0031] The enclosure 21 is comprised of an upper portion 36 and a lower portion 34 that are assembled to form the enclosure 21 with a front opening 32 for inserting the tray 22 . The assembled enclosure 21 defines a substantially hollow interior 19 within the upper portion 36 and the lower portion 34 . The enclosure 21 may be made of any suitably strong, temperature-resistant material, such as metal or heat-resistant plastic.
[0032] Referring now to FIG. 1B , details of the rear of the press 20 may be appreciated. The rear of the enclosure 21 is provided with ventilation openings 60 . An internal fan 80 exhausts warm air from within the enclosure 21 during a cooling cycle described below. The power supply cord 50 is preferably retractable within the enclosure 21 of the press 20 .
[0033] Referring to FIG. 1C , one of the safety features of the press 20 may be appreciated. A child resistant latching mechanism 54 is provided. The child resistant latch 54 comprises one or more screw fasteners. The heads of the fasteners are preferably recessed below the surface of the enclosure 21 when fully latched, making the screws difficult for young children to operate without the assistance of a tool. Because the latch mechanism 54 is located on the bottom of the enclosure and requires a tool to operate, the latch mechanism 54 is not readily operable by underage children. By limiting the ability of children to open the enclosure 21 , the risk of a burn or an electrical shock to a child by accessing energized elements within the press 20 is reduced. Other appropriate child proof latching mechanisms that may be known in the art may also be used.
[0034] By referring now to FIG. 2 , internal details of the press 20 may be understood. The tray support plate 94 described above is shown fully inserted within the lower housing 34 of the enclosure 21 . A pair of tray guides 30 are supported by side frames 82 disposed within the lower housing 34 . Each tray guide 30 defines an elongated guide slot. The tray support plate 94 slidably engages the tray guide slots, allowing the tray support plate 94 carrying a tray 22 to slide into or out of the press 20 . Preferably, a drawer guide 119 may also be used to support the tray support plate 94 ( FIG. 7A ).
[0035] When the tray support plate 94 is fully inserted within the enclosure 21 of the press 20 , leaf springs 92 mounted to a fixed support within the hollow interior 119 are biased to hold the tray 22 in a lowered position on the tray support plate 94 . In the lowered position, the tops of fuser beads 25 disposed in a mold 17 placed in the bead mold holder 24 of the tray 22 are held away from contact with a heating plate 120 , described below.
[0036] A linear actuator mechanism 90 may be provided in one embodiment to lift the tray 22 to a raised position above the tray support plate 94 . In the raised position, the tops of fuser 25 beads disposed in a mold 17 supported by the tray 22 are placed in contact with the heating plate 120 , described below. The linear actuator mechanism 90 may be comprised of a plurality of solenoids 90 disposed within the lower housing 34 . When energized, the solenoids 90 lift the tray the tray 22 away from the tray support plate 94 against the force of the tray springs 92 to the raised position. When the solenoids 90 are de-energized, the springs 92 return the tray 22 to the lowered position.
[0037] An electrically operated latching mechanism 100 may be provided in one embodiment for holding the tray 22 in position. The latching mechanism 100 can be electrically energized to hold the tray support plate 94 in position within the press 20 during a heating operation and released to allow the tray support plate 94 to be withdrawn from or inserted into the press 20 . In the illustrated embodiment, the latching mechanism 100 comprises a solenoid-operated latch 100 . When the solenoid 100 is energized, the plunger of the latching solenoid 100 rises to engage an opening in the tray support plate 94 , holding the tray 22 in place while the solenoid 100 is energized. De-energizing the latching solenoid 100 lowers the plunger, unlatching the tray support plate 94 . Alternatively, a solenoid 100 with the opposite operating sense may be employed, so that the tray support plate 94 is latched by de-energizing the solenoid 100 and unlatched by energizing the solenoid 100 .
[0038] The ventilation fan 80 disposed within the housing of the press 20 draws ambient air within the enclosure 21 through ventilation openings 60 in order to cool the fused beads 25 after a heating cycle. The fan 80 exhausts the heated air outside of the enclosure 21 . Preferably the fan 80 is positioned and operated to exhaust the air away from the front opening 32 at the front of the press 20 so that the heated air is not directed towards a user operating the press 20 .
[0039] Sensors 224 disposed within the housing are provided to detect conditions that indicate a safe or unsafe condition for operating the press 20 . One or more position detecting sensors 28 are located at the ends of a tray guide slot to detect whether or not the tray support plate 94 is fully inserted within the press 20 . The sensors may include photoelectric sensors comprising a light emitter element and a photo detector element separated by a gap positioned at the end of the tray guide slot. When the tray support plate 94 is not fully inserted, the light from the light emitter is detected by the photo detector element. When the tray support plate 94 is fully inserted, the plate 94 shadows the photo detector, interrupting the light from the light emitter element. Monitoring the output response of the photo detector provides an indication of whether the tray support plate 94 is fully inserted.
[0040] A proximity detector sensor 112 detects whether the upper enclosure housing 36 is in place, sealing off access to the internal components of the device from users during operation. The proximity sensor may be a microswitch 112 mounted on a portion of the lower housing 34 or a lower housing component, such as the tray guide support frame 82 . The proximity switch condition, closed or open, may be monitored to detect the state of assembly of the housing for the press 20 .
[0041] Referring now to FIG. 3 , the details of the heating plate assembly 115 in one embodiment may be appreciated. Preferably the components of the heating plate assembly 115 are installed within the upper housing 36 , allowing access to the region between the heating plate 120 and the lower assembly when the enclosure 21 is opened. Alternatively, the components of the heating assembly 115 may be mounted from supports fixed in the lower housing 34 .
[0042] A flat heating plate 120 made of a thermally conductive material, such as stainless steel or other metal, is disposed within the upper housing 36 and supported by a plurality of insulated mounts 124 from the upper housing 36 . The insulated mounts 124 may be resilient mounts that yield under a vertical pressing force to allow the press 20 to accommodate beads 25 of varying heights being pressed against the heater by the tray actuators described above. Alternatively, larger beads 25 may be accommodated by providing resilient supports for the tray positioning actuators.
[0043] The heating plate 120 is provided with a heating element 130 . The heating element 130 may be a resistive heating element 130 that converts electrical energy to heat when a current is passed through the element 130 . The heating element 130 may be embedded in the heating plate 120 , or alternatively, may be disposed on a surface of the heating plate 120 .
[0044] The lower surface of the heating plate 120 may be provided with a non-stick coating to prevent melted bead material from sticking to the surface of the heating plate 120 . Preferable the non-stick coating is a thin layer of a polymeric material, such as polytetrafluoroethylene (PTFE). Other materials may be used provided that they are stable under the anticipated temperatures for the heating plate 120 , have non-stick properties so that they do not adhere to the material of the beads 25 , and which do not chemically interact with the bead material.
[0045] A temperature sensor 132 may be provided on the heating plate 120 for monitoring the temperature of the heating plate 120 . The temperature sensor 132 may be a component whose electrical properties very with temperature, such as a temperature sensitive resistor or thermister. Alternatively, a temperature sensitive switch (not shown) that opens or closes at a fixed or preset temperature set point can provide an indication of whether the heating plate temperature is above or below a given point. Alternatively, the heating element 130 may be comprised of a material whose resistance varies with temperature so that measuring the voltage and current associated with the heating element 130 provides an indication of the heating plate 120 temperature. For example, the heating element 130 may be made of an alloy, such as nichrome, that has a positive temperature coefficient of resistance.
[0046] An insulating barrier 122 may be disposed between the inner surface of the upper housing 36 and the heating plate 120 . The insulating barrier 122 is preferably composed of a thermally insulating material able to withstand the anticipated temperatures attained by the heating element 130 . Such materials as thermosetting plastics, mica or other suitable materials may be used. The insulating barrier 122 serves to keep the external surfaces of the enclosure 21 cool to the touch to prevent the development of hot spots on the enclosure 21 that may present a burn hazard to users.
[0047] By referring to FIGS. 1A and 4 , details of the safety control circuit 200 for the press 20 may be understood. The safety control circuit 200 comprises a memory 204 , a central processing unit (CPU) 202 and control interfaces 210 . A control bus 212 couples the memory 204 and control interfaces to the CPU 202 . The memory 204 may be comprised of random access memory (RAM) 206 and read only memory (ROM) 208 . The random access memory 206 may store instructions from an executing program and data, such as information read by the CPU 202 or generated as the result of calculations performed by the CPU 202 . The ROM 208 is a non-volatile storage area that stores fixed data and operating instructions to be executed by the CPU 202 . The CPU 202 reads program instructions stored by the memory 204 and executes the instructions to provide the functionality required by the control circuit 200 . The control interfaces 210 facilitate communications between the CPU 202 and components external to the control circuit 200 . The external components include the user interface components 230 and the device control components 220 . The user interface components 230 comprise the operator controls 232 that include the start button 42 used to initiate the electrically controlled operations of the press 20 . The indicator lights 234 are controlled by the central processing unit 202 to indicate the current state of the press 20 . The indicator lights may include a illuminator for the start button 42 to indicate that a heating cycle may be safely started, a red light 44 indicating that a heating cycle is in progress, a yellow light 46 indicating that the press 20 is executing a cooling cycle, and a green ready light 48 to indicate that the cooling is complete and that beads may be safely removed from the machine. The user interface 230 may also include an alphanumeric display 236 providing a descriptive indication of the operating state of the press 20 . The display 40 may provide an indication of the time remaining in a cooling cycle.
[0048] The operating condition of the machine is sensed and controlled by the CPU 202 via the device control components 220 . The device control components 220 include the interlocks 222 that inhibit unsafe operation of the machine, sensors 224 that detect conditions within the press 20 , and the actuators 226 via which conditions of the press 20 are set by the CPU 202 . Referring to FIGS. 2 and 3 , the interlocks 222 comprise the tray latch 100 that is operated to prevent the tray 22 from being removed from the press 20 during a heating cycle or prior to cooling down after a heating cycle. The actuators include the heating element 130 , which is energized to control the temperature of the heating plate 120 during a heating cycle, and the tray actuators, which are controlled to move the tray 22 towards or away from the heating plate 120 to position the beads into contact with the heating plate 120 for fusing and away from the heating plate 120 during a cooling cycle. The actuators further include the fan 80 used to provide cooling during a cooling cycle.
[0049] The sensors 224 include the tray position sensors 28 , the heater temperature sensor 132 , and the enclosure proximity sensor 112 described above.
[0050] By referring to the process diagram shown in FIG. 5 , and FIGS. 1A, 2 , 3 , and 4 , the control logic implemented by the safety control circuit 200 may be understood. As shown in FIG. 5 , operation of the control logic begins in the start state 302 . To begin operation from the start state fuser beads are placed in the bead pegboard, which is then placed in the holder 24 in the tray 22 . The tray 22 is placed on the tray support plate 94 . The tray support plate 94 is then pushed into the front slot 32 of the press 20 . While in the start state 302 , the control circuit 200 monitors the condition of the sensors 224 to detect if the device is prepared to enter the ready state 304 . The monitoring includes checks to ensure that the enclosure 21 is closed and that the tray support plate 94 and tray 22 are fully inserted using the sensors described above.
[0051] In the start state 302 , the indicator lights, including the illumination for the start button 42 and the illuminator light, are extinguished. Pressing the start button 42 while in the start state 302 has no effect on circuit operation. Once the initial safety checks are completed, the control circuit 200 enters the ready state 304 via path 322 . In the ready state 304 , the start button illumination is energized, indicating that the user may initiate a bead fusing operation by pressing the start button 42 . While in the ready state 304 , the control logic continues to monitor the sensors 224 , and if a not ready condition is sensed, such as the tray 22 being not fully inserted or the enclosure 2 ] being open, the control logic transitions back to the start state 302 via path 324 . A message may be generated and sent to the display 40 to indicate one or more of the conditions that caused the control logic to transition back to the start state 302 .
[0052] If the start button 42 is pressed while the control logic is in the ready state 304 , the control logic transitions to the heating state 306 via path 326 . In the heating state 306 , a heating cycle is initiated to fuse the tops of beads in the bead tray. The tray latch 100 is engaged to prevent the tray 22 from being retracted during the heating cycle. The tray actuators 90 are energized to raise the tray 22 so that the tops of the beads contact the heating plate 120 , and the heating element is energized and controlled to maintain the heating plate 120 at the desired predetermined temperature for fusing the plastic beads. The value for the predetermined temperature may be read from a storage location in the memory 204 . The state of the press 20 is indicated by illuminating the heating state indicator tight 44 on the press 20 . The display 40 may be driven by the control circuit 200 to indicate the heating state. The display 40 may alternatively provide a time display indicating the remaining duration of the heating cycle. The duration of the heating cycle may be a predetermined time period stored in the memory 204 of the control circuit 200 .
[0053] When the time period of the heating cycle expires, the control circuit 200 transitions to the cooling state 308 via path 328 . In the cooling state 308 , the control circuit 200 continues to engage the tray latch 100 preventing the tray 22 with the heated beads from being retracted. The heating element 130 is de-energized and a cooling fan 80 may be turned on to accelerate the cooling of the heated beads. The tray actuators 90 are de- energized, allowing the tray springs 92 to lower the tray 22 away from the heating plate 120 . The cooling state 308 may be indicated by using a yellow illuminated indicator 46 . The display 40 may be driven by the control circuit 200 to indicate the cooling state 308 . The display 40 may alternatively provide a time display indicating the remaining duration of the cooling cycle. The duration of the heating cycle may be a predetermined time period stored in the memory 204 of the control circuit 200 . Alternatively, the remaining duration of the cooling cycle may be calculated based on a temperature read from a sensor disposed within the press 20 . In one embodiment, the temperature sensor 132 used to monitor the heating plate temperature may be used to estimate the remaining time required for the cooling cycle. In another embodiment, a temperature sensor in the air stream may be used to estimate the remaining time required for the cooling cycle. In yet another embodiment, the display 40 may indicate an estimated temperature of the beads calculated from the expired duration of the cooling cycle and/or temperature information measured with the press 20 .
[0054] Once the time period for the cooling cycle has expired, the control logic transitions to the cooled state 310 via path 330 . In the cooled state 310 , the tray latch 100 is released allowing the tray support plate 94 to be withdrawn from the press 20 , providing access to the fused and cooled beads. In the cooled state 310 , a green all safe indicator 48 is illuminated to indicate that the beads are cooled to a safe temperature. The cooling fan 80 is turned off. Once the user withdraws the tray support plate 94 to access the tray 22 and the beads, the control logic transitions to back to the start state 302 via path 332 .
[0055] In the described embodiment the control logic is implemented using software stored in a computer readable medium with the device. The control logic (software) is executed by the processor 202 causing the processor 202 to perform the functions of the invention as described herein.
[0056] In another embodiment, the elements are implemented primarily in hardware using, for example, hardware components such as application specific integrated circuits (ASICs). Implementation of the hardware state machine in order to perform the functions described herein wilt be apparent to persons skilled in the relevant art(s).
[0057] In yet another embodiment, elements are implemented using a combination of both hardware and software.
[0058] Additional safety checks may be performed during the states described with the logic control transitioning or remaining in the start state 302 when a safety check fails. For example, an abnormally high current may indicate that a solenoid actuator is restricted from making a full stroke, indicating that the tray path to the heating plate 120 may be blocked. A low or zero current value may indicate that the solenoid coil has failed. The current provided to the heating element 130 may also be monitored, with abnormally high or low currents being indicative of a failed or shorted heating element. The failed conditions may result in a diagnostic message being sent to the display 40 . A level sensor may be included to indicate the orientation of the bead fuser. The control logic may maintain the device in the start state 302 when the level sensor indicates that the bead fuser is not properly oriented. One skilled in the art would appreciate that sensors monitoring additional conditions may be interfaced to the control circuit to detect additional potentially unsafe conditions for operating the press 20 .
[0059] Preferably, the state indicator lights are of the red, green and yellow in color and are arranged in an orientation similar to a traffic signal light. The use of a familiar color scheme and orientation may allow younger users to successfully operate the press 20 . Alternative arrangements of the display may be used. For example, in one embodiment, color and arrangement of the indicators is chosen to provide an aesthetic appearance. The indicator light system may be omitted, with all of the relevant state information being provided via the alphanumeric display. The alphanumeric display provides additional information, which may allow older children and adults to diagnose problems with the press 20 and or to provide them with additional information concerning the operation of the press 20 .
[0060] The tray actuators are described as solenoid actuators in the described embodiment. In another embodiment, any electrically operated or actuated mechanism, which will produce a linear movement of the tray towards the heating plate, may be used. For example, the tray actuator may be a motor driven apparatus using a gearing arrangement to produce a vertical motion of the tray 22 . The operation of the motor may wind a spring, which reverses the direction of the tray when the motor is de-energized. Alternatively, the motor may be operated in the reverse direction to move the tray 22 away from the heating plate 120 .
[0061] In a preferred embodiment of the invention, illustrated in FIGS. 6-8 , a spring 92 is disposed within the enclosure 21 that biases the heating element 130 into an elevated position over the tray 22 ( FIGS. 7A and 7B ). At least one knob 27 mechanically connected to the heating element 130 at a forward end is captured in at least one inverted J-shaped slot 29 of the enclosure 21 . An upper end of each J-shaped slot 29 holds the knobs 27 in an elevated position, thereby holding the heating element 130 in the elevated position. The heating assembly 115 is pivoted at a pivot means 116 , such as a bolt 117 , at a rear end thereof ( FIG. 7A ). A lower end of each J-shaped slot 29 allows each knob 27 to fall into a lowered position, thereby allowing the heating element 130 to assume a lowered position such that the heating element 130 achieves close mutual proximity with the tray 22 , and contacts any beads 25 that are resting on the tray 22 in order to fuse the beads 25 together ( FIG. 7C ).
[0062] In such an embodiment, wherein the heating element 130 is movable between an elevated and a lowered position, once the beads 25 are fused they may stick to the heating element 130 when same is raised to the elevated position. As such, a generally horizontal second slot 33 is further included in the face 18 of the enclosure 21 ( FIGS. 7D and 8 ), and a scraper 35 may be introduced therein to pry the fused beads 25 away from the heating element 130 .
[0063] The control circuit 200 in such an embodiment may be altered slightly from that previously detailed. In such an embodiment, the control circuit 200 may, upon depression of a power switch 42 , energize the heating element 130 if the proximity detector sensor 112 indicates that the tray 22 is directly under the heating element 130 and that the tray support means 94 is fully inserted into the slot 32 . Upon actuation of the heating element 130 , the temperature sensor 132 indicates when the heating element 130 has reached a predefined operating temperature sufficient to fuse the beads 25 . At this point, a “ready to melt” indicator light 44 is actuated, signaling to the user that he may use the knobs 27 to lower the heating element 130 onto the beads 25 . A timing means of the control circuit 200 is then initiated, and upon the expiration thereof the heating element 130 is de-energized. At such a time, a “done melting” indicator light 48 is actuated, signaling to the user that the knobs 27 may be lifted and set into the raised position to raise the heating element 130 . A second cooling timing means is at this point initiated, and upon the expiration of same a “finished” indicator light 48 is actuated, alerting the user that sufficient cooling time has elapsed and that the user may remove the beads 25 from the enclosure 21 . If the beads 25 have stuck to the heating element, the scraper 35 may be inserted into the second slot 33 to dislodge the beads 25 from the heating element 130 . Preferably, a portion 23 of the enclosure 21 is transparent ( FIG. 8 ) so that the user may see inside the enclosure 21 to determine if the beads 25 have stuck to the heating element 130 , and in order to direct the scraper 35 accurately between the beads 25 and the heating element 130 .
[0064] To prevent the tray 22 from being removed while the heating element 130 is in the lowered position, the heating assembly 115 may further include a locking post 105 ( FIGS. 7A and 7C ) and the tray support 94 may include a locking post receiving means 106 ( FIG. 6 ). The locking post 105 engages the locking post receiving means 106 when the heating element 130 is not in the raised position ( FIG. 7C ), thereby preventing the tray support means 94 from sliding out of the enclosure interior 19 .
[0065] It is to be understood that the present invention is not limited to the embodiments described above. For example, the exactly type, placement, and state indications of the various indicator lights 44 , 46 , 48 may be varied in any number of ways. Further, a different number of such indicator lights may be used, for example, with or without the alphanumeric display 40 . Further, the mechanism used to bring the heating plate 130 into contact with the beads 25 may be varied in a wide variety of ways. As such, the present invention encompasses any and all embodiments within the scope of the following claims. | The press for fusing beads heats the tops of beads to fuse the beads together, fixing them in a pattern. The press includes an enclosure having a slot defined in the front face. A heating plate having a heating element is mounted within the enclosure. A tray, which holds the beads to be fused, is placed on a tray support that slides within the open slot to a position under the heating plate. A control circuit senses the position of the tray support, and when the tray is in position beneath the heating plate, allows an operator to initiate a timed heating cycle and locks the tray in place. When the heating cycle is initiated, the heating plate is brought into close proximity with the tray, placing the tops of the beads into contact with the heating plate and energizing the heating element to heat the heating plate to a predetermined temperature. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates to the field of fenestration including the mounting of doors, windows, skylights, and the like in building walls, ceilings and the like, and more particularly to a jamb mounting assembly that reduces the amount of labor, time and materials needed for installation of a jamb.
BACKGROUND OF THE INVENTION
[0002] Conventional methods for installing a door jamb, window jamb or the like in a building wall or roof have generally involved positioning the jamb in a rough opening and filling the gaps between framing members of the opening and the jamb with wood shims. Properly trimming and installing the shims between the jamb and the frame defining the opening requires a considerable amount of time, skill and effort to properly fit the jamb in the opening so that the jamb is plumb. After the shims have been properly positioned, nails are driven through the jamb and the shims into the supporting framing members defining the opening. Thereafter, protruding pieces of the shims, if any, are cut flush with the edge of the jamb.
[0003] It is of course desirable to eliminate the use of shims and to simplify jamb installation. To this end, numerous efforts have been directed toward simplified, shimless jamb mounting systems. While many of these systems have very substantially reduced the amount of time and effort needed to install a jamb in a building panel structure, such as a wall or roof, further improvements are desirable. In particular, it would be desirable to reduce the number of fasteners needed for jamb installation and to provide simpler, easier to manufacture and less expensive jamb mounting brackets, and to provide a jamb mounting assembly that may be at least partially pre-installed on the jamb prior to shipment from the factory.
SUMMARY OF THE INVENTION
[0004] In one aspect of the invention, a building fenestration is provided which includes a jamb positioned in an opening defined by a building panel structure, at least one bracket receiving slot on an outwardly facing planar surface of the jamb, and a bracket having first and second legs at a right angle to each other, the first leg of the bracket received in the bracket receiving slot and the second leg of the bracket fastened to the building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate defined on or attached to the jamb. In accordance with this aspect of the invention, the jamb may be mounted in a building panel opening by positioning the jamb in the opening with one or more bracket receiving slots pre-defined or installed on outwardly facing planar surfaces of the jamb, the jamb being positioned so that it is plumb with the opening, inserting the first leg of the bracket into the bracket receiving slot and fastening the second leg of the bracket to the building panel structure.
[0005] In accordance with another aspect of the invention, there is provided a jamb mounting assembly comprising a jamb having planar outwardly facing peripheral surfaces; a bracket receiving slot on at least one of the planar outwardly facing peripheral surfaces of the jamb; and a bracket having first and second legs at a right angle to each other, the first leg of the bracket configured to be received in the bracket receiving slot and the second leg of the bracket configured for attachment to a building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate. In accordance with this aspect of the invention, installation is further simplified by providing a jamb having premounted or pre-defined bracket receiving slots, whereby installation of the jamb may be achieved by steps generally involving positioning of the jamb in an opening defined in a building panel structure, the jamb being positioned plumb with the opening, inserting the first leg of a panel bracket into each of the bracket receiving slots and fastening the second leg of each bracket to the building panel structure.
[0006] In accordance with another aspect of the invention, there is provided a jamb mounting assembly comprising a substantially flat plate adapted to be fastened to a planar outwardly facing peripheral surface of a jamb to define a bracket receiving slot, and a bracket having first and second legs at a right angle to each other, the first leg of the bracket configured to be received in the bracket receiving slot, and the second leg of the bracket configured for attachment to a building panel structure. The jamb mounting assembly in accordance with this aspect of the invention may be used on generally any jamb having planar outwardly facing peripheral surfaces.
[0007] In another aspect of the invention, there is provided a bracket for mounting a jamb to a wall with or without a bracket receiving slot. The bracket includes first and second legs at a right angle to each other and tangs projecting at a right angle from one of the legs to facilitate fastening of the bracket to the jamb.
[0008] In a further aspect of the invention, there is provided another bracket for mounting a jamb to a wall with or without a bracket receiving slot. This bracket includes first and second legs at a right angle to each other and tabs projecting at a right angle from one of the legs to facilitate fastening of the bracket to the jamb.
[0009] These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a fragmentary perspective view of a rough opening in a building wall that is about to receive a door jamb.
[0011] FIG. 2 is an enlarged fragmentary perspective view of the door jamb shown in FIG. 1 to illustrate certain details.
[0012] FIG. 3 is fragmentary, side view of the door jamb show in FIG. 2 .
[0013] FIG. 4 is a perspective view of a bracket for securing a jamb in a rough opening.
[0014] FIG. 5 is fragmentary, front elevational view of a jamb installed in a rough opening employing the bracket shown in FIG. 4 .
[0015] FIG. 6 is a fragmentary side view of an alternative embodiment of a jamb having an integrally formed bracket receiving slot.
[0016] FIG. 7 is a perspective view of an alternative bracket for securing a jamb in a rough opening.
[0017] FIG. 8 is a fragmentary perspective view of the bracket shown in FIG. 7 being used to secure a jamb in a rough opening.
[0018] FIG. 9 is a fragmentary perspective view of another alternative bracket being used to secure a jamb in a rough opening.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] Shown in FIG. 1 is a rough opening 10 in a wall structure 12 formed by studs 14 , and header 16 supported by liner members 18 . Wall structure 12 may be covered with drywall panels 20 or the like to provide a finished wall, either before or after installation of jamb 22 in accordance with the invention.
[0020] The jamb mounting assemblies of this invention may be used for generally any type of building fenestration, including doors, windows, skylights and the like. In general, such fenestrations may be provided in accordance with this invention in various building panel structures, including exterior and interior wall structures, and roof structures.
[0021] As shown in greater detail in FIG. 2 , outwardly facing peripheral surfaces 23 of jamb 22 are provided with panel bracket receiving slots 26 . As shown in FIGS. 2 and 3 , panel bracket receiving slot 26 may be defined between one of the outwardly facing planar surfaces 23 of jamb 22 and a substantially flat plate 28 . The expression “substantially flat” as used to describe plate 28 is meant to encompass the fact that plate 28 is formed or bent slightly to allow flush mounting of opposite ends 30 and 31 of plate 28 to surface 23 of jamb 22 while allowing a sufficient gap between the ends of plate 28 to define a slot 26 into which a leg of a bracket may be received. Alternatively, as shown in FIG. 6 , plate 28 A can be formed as an integral section of the material used to fabricate jamb 22 . This may be achieved such as by cutting and stamping operations. Thus, bracket receiving slot 26 may be defined by pre-installed plates 28 fastened to surface 23 of jamb 22 with fasteners 32 , 34 (screws, rivets or the like) by the jamb manufacturer; attached by the jamb installer; or integrally pre-formed on jamb 22 .
[0022] After installation, pre-installation or integral forming of bracket receiving slots 26 on jamb 22 , jamb 22 is positioned in plumb in opening 10 . Thereafter, a bracket 34 is used to secure jamb 22 in plumb in rough opening 10 . Bracket 34 includes a first leg 36 and a second leg 38 which is at a right angle to leg 36 . A forward edge 40 of first leg 36 is inserted into bracket receiving slot 26 until second leg 38 is flush against finish panels 20 (e.g., drywall or the like) or flush against liner 18 or stud 14 . Thereafter, each bracket 34 may be secured to the building panel structure (e.g., wall structure or ceiling structure) with a single fastener (such as a screw or nail). However, bracket 34 may be configured for attachment with multiple fasteners if desired. In the illustrated embodiment, a single fastener aperture 42 is provided through second leg 38 of bracket 34 .
[0023] In those cases in which bracket 34 is attached directly to studs 14 or liner member 18 , drywall or other finish wall material 20 may be subsequently installed over bracket 34 . In the case where bracket 34 is installed over drywall or other finish wall material 20 , exposed surfaces of leg 38 of bracket 34 may be primed, covered with spackle or the like to facilitate application of paint, wallpaper or the like. Thus, the invention facilitates installation of a door or window jamb in a wall or installation of a skylight in a roof generally any time after framing of the walls or roof have been completed. After jamb 22 and finish wall material 20 have been installed, various trim options may be employed to cover the gap between jamb 22 and the wall and to conceal brackets 34 . If desired, insulation (such as foam or glass fiber) may be inserted into the gap between jamb 22 and the wall prior to adding the finish trim.
[0024] As can be seen by reference to FIG. 2 , flat plate 28 can be located entirely between corners 41 and 42 of the outwardly facing planar surface 23 of jamb 22 . This arrangement allows exceptional flexibility with respect to the use of exposed trim for concealing the gap between rough opening 10 and surfaces 23 of jamb 22 . Further, because plate 28 is substantially flat and/or is located entirely between the edges of the outwardly facing planar surfaces 23 of jamb 22 , pre-installed plates 28 have a very low profile that should not interfere with or require modification to packaging materials or shipping procedures for pre-hung doors, pre-hung windows and the like.
[0025] In the illustrated embodiment, the details of which are shown in FIG. 2 , flat plate 28 includes a tab 48 which projects from a lateral edge of flat plate 28 and which extends through an aperture 50 defined in leg 38 of bracket 34 ( FIG. 4 ) when leg 36 of bracket 34 is inserted into slot 26 . As shown in FIG. 5 , tab 48 may optionally be bent at a right angle flush with the exposed surface of leg 38 or bracket 34 .
[0026] As shown in FIG. 4 , leg 38 of bracket 34 may be provided with one or more scribe lines 49 that may be aligned with a plumb line 51 ( FIG. 5 ) drawn on the wall, liner 18 , stud 14 or the like.
[0027] Leading edge 40 of leg 36 of bracket 34 may have a tapered shape that becomes progressively narrower away from second leg 38 , and may be curved to facilitate easier insertion of leg 36 of bracket 34 into slot 26 .
[0028] FIG. 7 shows an alternative bracket 50 having a first leg 36 and a second leg 38 , in which tangs 52 are provided. Tangs 52 project at a right angle from second leg 38 along a plane parallel to first leg 36 in the direction of leg 36 , and have sharp or pointed ends 54 that allow bracket 50 to penetrate an edge 56 of jamb 22 as shown in FIG. 8 to firmly secure bracket 50 to jamb 22 . Bracket 50 is otherwise generally similar to and used in a similar way to bracket 34 . However, bracket 50 may be used either with or without plate 28 or 28 A.
[0029] FIG. 9 shows another alternative bracket 60 having a first leg 36 and a second leg 38 , in which fastener tabs 62 are provided. Tabs 62 projects at a right angle from second leg 38 along a plane parallel to first leg 36 in a direction opposite leg 36 . Tabs 62 may be provided for firmly securing bracket 60 to outwardly facing planar surface 23 of jamb 22 . Bracket 60 is otherwise generally similar to and used in a similar way to bracket 34 . However, bracket 60 may be used either with or without plate 28 or 28 A, and is normally used before wall covering 20 is installed.
[0030] The various aspects of this invention provide a simple, fast, effective way to secure jambs to building panel structures such as wall structures and roof structures. In accordance with certain aspects of the invention, installation is further simplified by integrally forming or factory installing structure to define a bracket receiving slot, whereby after the jamb has been properly positioned in a rough opening, installation is completed by simply sliding a bracket into each of the bracket receiving slots provided and fastening each bracket to the building panel structure. The invention may be used with either new construction or during remodeling or renovation, and with or without finish material (e.g., drywall) applied to the building panel structure. Because the structure defining the bracket receiving slot is separate from the brackets until installation is nearly complete, bracket 34 is self-adjusting to various wall thicknesses with or without finish material applied to the building panel structure. For a typical installation, only one screw per bracket is needed. Thus, for a typical pre-hung door jamb installation, after proper positioning of the door and door jamb in a rough opening, installation is completed by merely inserting a bracket into each of the seven bracket receiving slots, and securing each of the brackets to the wall structure, such as with a single fastener (e.g., a screw).
[0031] Another advantage with the substantially flat configuration of plate 28 or 28 A is that it is very inexpensive, and therefore can be pre-installed or pre-formed on every jamb shipped from a manufacturer without interfering with an installer's ability to either employ brackets 34 as disclosed herein or to employ conventional installation methods if desired. In accordance with this aspect of the invention, incorporating pre-formed or pre-installed plates 28 or 28 A, manufacturers are provided with control over where and how often attachment of a jamb takes place, allowing positioning and placement of the jamb bracket to be controlled by the manufacturer. Because of the very simple, low profile and compact design of the structure ( 28 or 28 A) defining the bracket receiving slots 26 , structure 28 or 28 A does not interfere with or require any modification of typical shipping and delivery methods that are currently employed. The invention allows full insulation of the cavity defined between a jamb and a building panel structure because attachment of the jamb may be achieved by securement of brackets 34 to the interior side of an exterior wall. This allows the cavity to be filled, usually from the inside, with fiberglass or foam insulation to increase energy efficiency of the installation as whole, making the total unit more energy efficient in the completed fenestration. Because the installation is very simple and self-adjusting, poor workmanship issues are eliminated or very substantially reduced, decreasing warranty issues.
[0032] The above description is considered that of the preferred embodiment(s) only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment(s) shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents. | A building fenestration that reduces the amount of time, effort and expense associated with installing a jamb in a rough opening of a building panel structure includes a jamb positioned plumb in the opening, the jamb having outwardly facing planar surfaces, at least one bracket receiving slot on at least one of the outwardly facing planar surfaces of the jamb, and a bracket having first and second legs at right angles to each other, the first leg of the bracket received in the bracket receiving slot and the second leg of the bracket fastened to the building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate. | 4 |
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] This application claims the priority of German Priority document 102 23 870.7, filed May 29, 2002, the disclosure of which is expressly incorporated by reference herein.
[0002] The invention relates to an electromagnetic actuator.
[0003] An electromagnetic actuator, in particular for actuating a charge cycle valve of an internal combustion engine, generally has two switching magnets. There is an opening magnet and a closing magnet, between whose pole faces an actuating element is moveably mounted. Such an actuating element is, for example, an armature, arranged so as to be coaxially displaceable with respect to a valve axis, of a charge cycle valve, or a rotatably mounted pivoting armature. In actuators according to the principle of the mass oscillator, a prestressed spring mechanism acts on the actuating element, for example the armature. Two prestressed springs usually serve as the spring mechanism, one of the springs loading the charge cycle valve in the opening direction and the other loading the charge cycle valve in the closing direction. When the magnets are not excited, the actuating element is held in a position of equilibrium between the magnets by the valve springs.
[0004] In order to actuate the control element, for example an outlet valve of an internal combustion engine, which is connected to the actuating element, the magnets must be capable of applying high forces, in particular when the outlet valve opens. The respective end position of the valve must always be reliably reached in such cases when the valve opens and closes. In order to monitor the valve, it is advantageous to know the respective position of the valve precisely. In addition, variables which are not taken into account from the beginning and which vary over time and/or during the operation lead to a situation in which, for example, the position of equilibrium of an armature which is determined by the valve springs does not coincide with an energetic central position between the pole faces, and the actuation of the valve is thus adversely affected. Such changing variables are, for example, fabrication tolerances of individual components, thermal expansion of different materials, different spring stiffnesses of the two valve springs or else ageing and wear of individual components.
[0005] German reference DE 197 35 375 C1 discloses a solenoid valve in which the position of the armature is determined from pressure measurements using piezo-measuring elements under the spring foot points.
[0006] The present invention provides a device having an actuator for actuating a control element, in which device, the position of the control element during the operation of the actuator can be sensed as precisely as possible and over a large range.
[0007] The invention is based on a device having an electromagnetic actuator for actuating a control element, in particular a charge cycle valve of an internal combustion engine, the actuator including at least one elastic element provided for the purpose of elastic deformation with the elastic element being connected to a deformation sensor.
[0008] It is possible to use, for example, a spring or some other object which deforms elastically during the actuation of the control element as the elastic element. Such an elastic element is indirectly or directly operatively connected to the control element and changes its spatial shape when the control element is actuated. As a result, at least one of its outer faces and also an inner region of the control element is subjected to extension or compression. A deformation sensor is understood to be a sensor whose output signal is influenced by the extension or compression of an elastic element which is assigned to the sensor. This influencing process can take place optically, for example by optical analysis of the elastic element, electrically or mechanically, for example by means of a deformation of the elastic element. In the case of a mechanical influencing process, the deformation sensor is expediently permanently connected to the surface or to the interior of the elastic element. The fixed connection between the deformation sensor and the elastic element can be brought about by means of a materially joined connection, for example bonding. It can equally well be manufactured by means of a positively locking or a frictionally locking connection. The important factor for such a connection is that the mechanical deformation, for example a spatial compression or extension, is transmitted mechanically to the deformation sensor.
[0009] On the basis of the measurement of the deformation of the elastic element, it is possible to form reliable conclusions about the position of the control element. Such a measurement is largely independent of external circumstances such as temperature, soiling or electromagnetic fields and is not influenced either by ageing or wear phenomena of the electromagnetic actuator or of its components. The position of the control element which is determined using the deformation sensor can be used to control and regulate the actuator.
[0010] In an advantageous refinement of the invention, the deformation sensor is a strain gauge. A strain gauge includes an electrical conductor which is mounted on a carrier, for example a film, and whose electrical resistance changes when the conductor deforms. It is possible to use a commercially available strain gauge, for example a metal strain gauge or a semiconductor strain gauge. The strain gauge is permanently applied to the surface of the elastic element so that it is compressed or extended when the elastic element is deformed. As a result, the electrical resistance of the conductor changes. The electrical resistance is thus a measure of the deformation of the elastic element and therefore also of the position of the control element. The strain gauge is, for example, bonded to the surface of the elastic element, and may be covered with a protective layer in order to protect it against external influences. The strain gauge can, however, also be integrated into an elastic element which is of multi-layer construction, for example. The precision of a deformation sensor which is configured in such a way is very high, while the mass of the sensor which is to be additionally moved with the control element is very small. Using a strain gauge as a deformation sensor, it is possible to determine the position of the control element very precisely and largely independently of external influences. In addition, a strain gauge is particularly simple to handle and economical to acquire.
[0011] In one preferred refinement of the invention, the deformation sensor is a Bragg grating sensor. A Bragg grating sensor is an optical fiber measuring sensor which includes a light guide, for example a glass fiber, in which a number of reflection planes which are arranged equidistantly in the axial direction have been produced. In order to measure the deformation using a Bragg grating sensor, laser light of a relatively wide wavelength range is injected into the light guide. The light which is reflected at the reflection planes, causes structural interference if the wavelength corresponds to twice the distance between the reflection planes, or to a multiple thereof. If the part of the light guide in which the reflection planes—the Bragg grating—are located is extended or compressed, the grating spacing changes. The structurally reflected wavelength is thus displaced. It is thus possible to use the displacement of the wavelength of the reflected light to draw conclusions about the change in the grating spacing and thus about the change in length of the light guide. If the Bragg grating sensor is permanently connected to the elastic element, it is extended or compressed along with the deformation of the elastic element. As a result, the grating spacing of the reflection planes is displaced. On the basis of the displacement of the wavelength of the reflected light, it is possible to determine the change in length of the part of the elastic element on which the glass fiber is mounted. By determining the relationship between a position of the control element and a deformation of the elastic element, it is possible to determine the position of the control element extremely quickly and accurately using the Bragg grating sensor. A Bragg grating sensor is also defined by the fact that it is insensitive to electromagnetic influences and that absolute values of the change in length can be interrogated at any time after the installation of the sensor by injecting light with a suitable wavelength range and subjecting the reflected light to spectral analysis. Furthermore, a Bragg grating sensor does not require any extensive electrical connections, which makes it particularly reliable even in an environment which is particularly subject to mechanical, chemical or electromagnetic stress. Furthermore, it is possible to use a Bragg grating sensor to precisely measure, thus permitting the position of the control element to be determined very precisely.
[0012] Bragg grating sensor can be mounted either on the surface of the elastic element, which is particularly simple, or be integrated into the elastic element itself. By introducing it into the elastic element, the Bragg grating sensor is particularly protected against external mechanical effects. Such an arrangement is particularly advantageous if the elastic element itself includes fibers in its structure, for example carbon fibers or glass fibers, or both, bound in a resin. The light guide of the Bragg grating sensor can then be easily integrated into the elastic element so that it is extremely durable and very reliable and supplies very precise measured values independently of external influences.
[0013] A plurality of deformation sensors are expediently connected to the elastic element. By attaching or assigning a plurality of deformation sensors to the elastic element, it is possible to determine the position of the control element very accurately and reliably. However, it is also possible to attach a plurality of deformation sensors to a plurality of elastic elements of the device. In this way, in each case one or more deformation sensors is expediently arranged on both springs of a charge cycle valve of an internal combustion engine. With such an arrangement it is possible to determine the position of the control element very precisely and also very reliably even if one of the sensors fails. The light guide can be configured in such a way that it contains two or even more Bragg grating sensors along its length. A Bragg grating sensor thus includes two or more light guide sections, each with a number of equidistantly formed reflection planes. It is possible to position a plurality of sensors in a light guide, and thus monitor the elastic element at a plurality of points, without a large degree of structural expenditure. It is particularly advantageous here to arrange a number of Bragg grating sensors with different characteristic frequencies in the light guide. The characteristic frequency of a Bragg grating sensor is the frequency of the reflected light in a mechanically uninfluenced state of the light guide. Each Bragg grating sensor reflects light with a frequency which—due to the deformation—fluctuates slightly about the characteristic frequency which is assigned to the respective sensor. If different sensors have different characteristic frequencies, that is to say a different reflection plane spacing, it is possible to determine, on the basis of the frequency of the reflected light, which Bragg grating sensor reflects the light. As a result, both the spatial location of the deformation and the degree of the deformation can be determined precisely.
[0014] The elastic element is preferably part of a spring mechanism of the actuator. The spring mechanism of the actuator experiences particularly large deflection when the control element is actuated. As a result, it is possible to measure the position of the control element precisely.
[0015] The elastic element can expediently be a helical compression spring or, in an alternative refinement, a torsion spring. The deflection of the springs, and thus their measurable deformation, is dependent, and possibly even proportional, to the deflection of, for example, a charge cycle valve. By means of the measurement signal of the deformation sensor, it is thus possible easily to draw conclusions about the deformation of the spring, and in turn about the position of the valve on the basis of the deformation. Such an arrangement permits precise, reliable and particularly easy-to-handle measurement of the position of the valve.
[0016] An evaluation unit for determining the deformation of the elastic element is expediently connected to the deformation sensor. This evaluation unit, for example a semiconductor module, is advantageously also simultaneously provided for determining the position of the control element on the basis of the deformation of the elastic element. This permits essentially continuous determination of the deformation or of the position of the control element.
[0017] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 shows a longitudinal section through a schematically illustrated actuator, and
[0019] [0019]FIG. 2 shows an enlarged detail of the actuator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] [0020]FIG. 1 shows a longitudinal section through a schematically illustrated actuator 1 for actuating a charge cycle valve 2 of an internal combustion engine (not illustrated in more detail). The actuator 1 has an electromagnetic unit with two electromagnets 4 , 6 , an opening magnet 4 and a closing magnet 6 . Each of the electromagnets 4 , 6 has a solenoid 8 , 10 which is wound onto a coil former (not illustrated in more detail), and a coil core 12 , 14 with two yoke limbs which form pole faces 16 , 18 with their end sides. Between the pole faces 16 , 18 a pivoting armature 20 is mounted so as to be capable of pivoting to and fro about an axis. The pivoting armature 20 acts on the charge cycle valve 2 via a play-compensating element 22 and via a valve stem 24 . The valve stem 24 is mounted in an axially displaceable fashion in a cylinder head 28 of the internal combustion engine by means of a stem guide 26 .
[0021] The actuator 1 also comprises a spring mechanism with two prestressed valve springs, specifically with a valve spring which is formed as a torsion spring 30 (see FIG. 2) and acts in the opening direction 32 , and with a valve spring which is formed as a helical compression spring 34 and acts in the closing direction 36 .
[0022] In the closed position of the charge cycle valve 2 , the pivoting armature 20 bears against the pole face 18 of the excited closing magnet 6 and is held by it. The closing magnet 6 further prestresses the torsion spring 30 which acts in the opening direction 32 . In order to open the charge cycle valve 2 , the closing magnet 6 is switched off and the opening magnet 8 is switched on. The torsion spring 30 which acts in the opening direction 32 accelerates the pivoting armature 20 beyond the position of equilibrium so that said pivoting armature 20 is attracted by the opening magnet 8 . The pivoting armature 20 strikes against the pole face 16 of the opening magnet 8 and is held tight by it. In order to close the charge cycle valve 2 again, the opening magnet 8 is switched off and the closing magnet 6 switched on. The helical compression spring 34 which acts in the closing direction 36 accelerates the pivoting armature 20 beyond the position of equilibrium to the closing magnet 6 . The pivoting armature 20 is attracted by the closing magnet 6 , strikes against the pole face 18 of the closing magnet 6 and is held tight by it.
[0023] Three deformation sensors 38 are mounted on the helical compression spring 34 . These deformation sensors 38 are strain gauges. The strain gauges 38 are permanently bonded to the surface of the helical compression spring 34 so that they are permanently connected to the surface. The three deformation sensors 38 are each coated with a protective layer (not illustrated in more detail) to protect them against external effects.
[0024] During an opening process of the charge cycle valve 2 , the helical compression spring 34 is pressed together and the three deformation sensors 38 are each simultaneously deformed. During a closing process of the charge cycle valve 2 , the helical compression spring 34 relaxes in the closing direction 36 , the deformation sensors 38 being in turn slightly deformed. The deformation sensors 38 have an electrical conductor with an electrical resistance. Depending on the geometric position of the electrical conductor on the strain gauge, the electrical resistance becomes larger or smaller in one direction or the other when the strain gauge is deformed. On the basis of a resistance value of each of the strain gauges, it is thus possible to determine deformation of the helical compression spring 34 and the position of the charge cycle valve 2 on the basis of said deformation.
[0025] The deformation sensors 38 are electrically connected to an evaluation unit (not shown in more detail in the figure) for determining the deformation of the helical compression spring 34 . This evaluation unit is also provided for determining the position of the charge cycle valve 2 on the basis of the deformation of the helical compression spring 34 .
[0026] When the charge cycle valve 2 moves in the opening direction 32 or closing direction 36 , not only the helical compression spring 34 but also the torsion spring 30 is deformed. This deformation is sensed by two deformation sensors 42 , 44 (shown in FIG. 2) which are configured as Bragg grating sensors. They each comprise reflection planes which are arranged equidistantly in a light guide 46 . The light guide 46 and the Bragg grating sensors are shown schematically in a basic view. During an opening or closing process of the charge cycle valve 2 , the torsion spring 30 is deformed in each case through torsion. The light guide 46 , which is arranged pre-extended on the torsion spring 30 , is extended to a greater or lesser degree when the torsion spring 30 is subject to torsion. As a result, the reflection planes of the deformation sensor 42 are extended. The light guide 46 is permanently bonded to the torsion spring 30 at the location on the light guide 46 where the deformation sensor 44 is arranged. The light guide 46 does not extend perpendicularly with respect to the axial direction of the torsion spring 30 at this location so that the deformation sensor 44 is extended or compressed when the torsion spring is subjected to torsion.
[0027] While the actuator 1 is operating, laser light with a relatively wide wavelength range is injected into the light guide 46 by a laser which is integrated into an evaluation unit 48 . This light is, in each case, partially reflected by the deformation sensors 42 , 44 . The wavelength of the reflected laser light is twice a plane spacing or a multiple thereof. If the light guide 46 is extended, and the deformation sensors 42 , 44 along with it, the spacing between the equidistant reflection planes in the light guide 46 increases. As a result, the wavelength of the reflected light also becomes longer. The reflected laser light is subjected to spectral analysis by the evaluation unit 48 . A wavelength which is determined by the evaluation unit 48 is processed to form an output signal which is fed to a further evaluation and control unit which is not illustrated in more detail in the figure. This unit processes the output signal to form a further signal which corresponds to the position of the charge cycle valve 2 and is used to control the actuator 1 .
[0028] The light guide 46 comprises two deformation sensors 42 , 44 whose equidistantly arranged reflection planes each have a different plane spacing. The laser light which is injected in broadband form is reflected both by the deformation sensor 42 and the deformation sensor 44 with the respective characteristic frequency. On the basis of the frequency of the reflected laser light, the evaluation unit 48 determines from which of the two deformation sensors 42 , 44 the reflected light originates. On the basis of the displacement of the wavelength of the reflected light which results from the deformation, the deformation of the torsion spring 30 can thus be determined at any location at which one of the deformation sensors 42 , 44 is situated.
[0029] Using both the deformation sensor 38 and the deformation sensors 42 , 44 , it is possible to determine the position of the charge cycle valve 2 very easily and very precisely as well as also very reliably. The deformation sensors 38 , 42 , 44 are insensitive to mechanical and thermal loading and are also suitable for mutual monitoring. The position of the charge cycle valve 2 which is determined using the deformation sensors 38 , 42 , 44 is used to control and regulate the actuator 1 .
[0030] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof. | A device having an electromagnetic actuator for actuating a control element, in particular a charge cycle valve of an internal combustion engine. The actuator includes at least one elastic element, for example, a valve spring, provided for the purpose of elastic deformation. The elastic element is connected to a deformation sensor providing a signal making it possible to determine the deformation of the elastic element, and to determine the position of the control element. | 5 |
CLAIM PRIORITY
[0001] This application reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application earlier filed in the Korean Intellectual Property Office on Dec. 19, 2008 and there duly assigned Serial No. 10-2008-0130380.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] A method of preparing nano phosphor, and a display device including the nano phosphor.
[0004] 2. Description of the Related Art
[0005] A phosphor is a material exhibiting luminescence characteristics upon energy excitation. In general, phosphor is used in various devices for a light source, such as a mercury fluorescent lamp, a mercury-free fluorescent lamp, an electron emission device, a plasma display panel (PDP), etc. Also, along with the development of new multimedia devices, phosphors are expected to be used in a wide variety of applications in the future.
[0006] Nano phosphors include small particle size, separable property among particles, excellent luminescence efficiency, a lowered light scattering effect, and so on. Phosphors made of small and well-separable particles usually exhibit a considerable reduction in luminescence efficiency. To compensate for a reduction in light emission efficiency, one attempt among conventional attempts has been to raise a heating temperature or increase a heating time.
[0007] In order to overcome such problems, heat spraying, hydrothermal methods, sol-gel synthesis methods, and laser crystallization methods have been suggested as alternative methods for increasing light emission efficiency. Despite having high quality characteristics, however, uses of such methods are severely limited due to high operating and equipment costs, and difficulty in upscale manufacturing.
SUMMARY OF THE INVENTION
[0008] One or more embodiments include a method of preparing a nano phosphor having high crystalline properties.
[0009] One or more embodiments include a nano phosphor prepared using the method and having high crystalline properties.
[0010] Additional aspects will be set forth in part in the description which follows and, in part, will be apparent from the description, or can be learned by practice of the invention.
[0011] To achieve the above and/or other aspects, one or more embodiments may include a method of preparing a nano phosphor, the method including forming a metal oxide nanoparticle via a low-temperature synthesis process, forming a mixture by mixing the metal oxide nanoparticle and an inorganic salt and annealing the mixture.
[0012] The metal oxide nanoparticle may include a material selected from a group consisting of a lanthanides-based borate compound, a lanthanium-based borate compound and an yttrium-based borate compound. The metal oxide nanoparticle may include (Y 1-a-b ,Gd a )BO 3 :M b (where M is Eu, La, Tb, Pr, Nb, Sm, Gd, Eb or Yb, ‘a’ satisfies 0≦a≦0.40, and ‘b’ satisfies 0.01≦b≦0.30). The low-temperature synthesis process may be performed at a temperature equal to or lower than 500° C. The low-temperature synthesis process may be selected from a group consisting of a precipitation process, a hydrothermal process, or a solvothermal process. The inorganic salt may include at least one material selected from a group consisting of NaBO 2 , LiBO 2 , KBO 2 , MgSO 4 , Li 2 SO 4 , Na 2 SO 4 , K 2 SO 4 , MgCl 2 , CaCl 2 , SrCl 2 , BaCl 2 , Li 2 CO 3 , Na 2 CO 3 , K 2 CO 3 , Rb 2 CO 3 , LiCl, NaCl, KCl, RbCl and CsCl. The inorganic salt may include a nonmetallic component included within the metal oxide nanoparticle. The annealing may be performed using microwaves. The nano phosphor may include a (Y,Gd)BO 3 :Eu phosphor. The process may further include post-annealing the mixture at a temperature in the range of 800° C. to 1500° C. after the annealing. The annealing may occur at a pressure of 40 atmospheres. The mixture may include a solvent, the inorganic salt being dissolved in the solvent.
[0013] According to another aspect of the present invention, there is provided a nano phosphor prepared according to the above process. The nano phosphor may be a (Y,Gd)BO 3 :Eu phosphor.
[0014] According to another aspect of the present invention, there is provided a display device that includes the nano phosphor as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicated the same or similar components, wherein:
[0016] FIG. 1 illustrates mechanism of removing defects in yttrium borate-based nano phosphors according to an embodiment of the present invention;
[0017] FIG. 2 is a graph of a result of X-Ray Diffraction (XRD) of (Y,Gd)BO 3 :Eu nano phosphors prepared according to an embodiment of the present invention;
[0018] FIG. 3 is a scanning electron microscopy (SEM) image of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to an embodiment of the present invention;
[0019] FIG. 4A is an emission photoluminescence (PL) graph of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to an embodiment of the present invention and measured at an excitation wavelength of 254 nm;
[0020] FIG. 4B is a PL graph of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to an embodiment of the present invention and measured at an excitation wavelength of 147 nm of vacuum ultraviolet rays;
[0021] FIG. 5A is a PL graph of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to an embodiment of the present invention and measured at an excitation wavelength of 254 nm;
[0022] FIG. 5B is a PL graph of (Y,Gd)BO 3 :Eu nano phosphors prepared according to a conventional technique and measured at an excitation wavelength of 254 nm;
[0023] FIG. 6A is a transmission electron Microscopy (TEM) image of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to an embodiment of the present invention;
[0024] FIG. 6B is a fast Fourier transform (FFT) diffractogram image of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to an embodiment of the present invention;
[0025] FIG. 7A is a TEM image of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to a conventional technique; and
[0026] FIG. 7B is a FFT image of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to a conventional technique.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the principles for the present invention.
[0028] Metal oxide nanoparticles of nano phosphors are synthesized using a low-temperature synthesis method in which the sizes and shapes of synthesized particles may be easily controlled. Examples of low-temperature synthesis techniques include a precipitation technique, a hydrothermal technique, a solvothermal technique, and a wet synthesis technique using microwaves. The precipitation technique, the hydrothermal technique, the solvothermal technique, and the wet synthesis technique using microwaves may use a generally known process that is not particularly limited.
[0029] For example, in the precipitation technique, metal oxide nanoparticles may be synthesized by dissolving a precursor and then dropwise adding a basic solvent such as an ammonia solution, a Na 2 CO 3 solution or NaOH into the resultant. In addition, in the hydrothermal technique or the solvothermal technique, metal oxide nanoparticles may be synthesized by dissolving a precursor together with urea and then increasing the temperature.
[0030] The low-temperature synthesis technique may be performed at a temperature equal to or lower than about 500° C., preferably, in the range of about 25° C. to about 200° C., and may use a general heating means such as a heater or microwaves. For example, metal oxide nano-scale precursor particles may be synthesized within 10 minutes to 20 minutes using microwaves.
[0031] Examples of the metal oxide nanoparticles may include a lanthanides-based borate compound, a lanthanium-based borate compound, and an yttrium-based borate compound. The yttrium-based borate compound may be, for example, (Y 1-a-b ,Gd a )BO 3 :M b (where M is Eu, La, Tb, Pr, Nb, Sm, Gd, Eb, or Yb, ‘a’ satisfies 0≦a≦0.40, and ‘b’ satisfies 0.01≦b≦0.30).
[0032] The metal oxide nanoparticles may have an average particle size in the range of about 1 nm to about 1,000 nm, preferably, in the range of about 50 nm to about 400 nm. However, the metal oxide nanoparticles prepared using a low-temperature synthesis technique is likely to have defects on a surface or crystal thereof. In addition, such surface or crystalline defects may reduce the crystalline properties and luminescent efficiency of the nano phosphors.
[0033] According to an embodiment of the present invention, nano phosphors are prepared by mixing the metal oxide nanoparticles prepared using a low synthesis technique with an inorganic salt and then annealing the mixture. The inorganic salt may compensate for the defects in the metal oxide nanoparticles. For example, the inorganic salt may be one or more of NaBO 2 , LiBO 2 , KBO 2 , MgSO 4 , Li 2 SO 4 , Na 2 SO 4 , K 2 SO 4 , MgCl 2 , CaCl 2 , SrCl 2 , BaCl 2 , Li 2 CO 3 , Na 2 CO 3 , K 2 CO 3 , Rb 2 CO 3 , LiCl, NaCl, KCl, RbCl and CsCl.
[0034] The surface or crystalline defects of the metal oxide nanoparticles are likely to occur at a nonmetallic ion site. Thus, the inorganic salt may include a nonmetallic component included in the metal oxide nanoparticles. For example, when the metal oxide nanoparticles are borate-based oxides, NaBO 2 , LiBO 2 , or KBO 2 , that include boron as the nonmetallic component, may be used as the inorganic salt.
[0035] The inorganic salt may be used in the form of a solution. A solvent used to form the solution is not limited to any particular solvent as long as the solvent may dissolve the inorganic salt. Examples of the solvent may include water, methanol, ethanol, glycerol, ethylene glycol, and diethylene glycol.
[0036] The concentration of the inorganic salt in the solution is not particularly limited. For example, the concentration may be in the range of about 0.01 mol/liter to about 1 mol/liter. When the concentration exceeds this range, the inorganic salt may not sufficiently compensate for the defects, or a side reaction may occur due to inorganic salt that is not dissolved.
[0037] If necessary, the solution may further include a dispersant in order to increase the dispersibility of the metal oxide nanoparticles, etc. The dispersant may be one or more of citric acid, acetic acid, sodium acetate, ammonium acetate, oleic acid, sodium oleate, ammonium oleate, ammonium succinate, polyacrylate, glycine, and acylglutamate. The dispersant may additionally prevent agglomeration of the metal oxide nanoparticles.
[0038] Alternatively, the metal oxide nanoparticles may be prepared using a low-temperature synthesis technique, may be separated and washed, and then may be mixed with the inorganic salt. Such a mixing operation may be performed in the solvent as described above.
[0039] Then, annealing is performed on the mixture. At this time, general heating means, such as a convection oven, a heater or microwaves, may be used as a heat source. The annealing may be performed at a temperature in the range of about 100° C. to about 300° C. The time required for the annealing may vary according to the type of the heat source.
[0040] When microwaves are used as a heat source, the crystalline properties of the nano phosphors may be effectively increased within a short period of time while preventing growth of the particle size of the nano phosphors and preventing aggregation of the nano phosphors. The mixture is rapidly heated due to a direct reaction between radiated microwaves and the solvent/reactant so that the reaction time is reduced due to the kinetics of the microwaves. As a result a local super heating effect may be obtained, thereby effectively compensating for the surface and crystalline defects of the metal oxide nanoparticles. The microwaves may be electromagnetic waves with a frequency in the range of about 300 MHz to about 300 GHz.
[0041] The annealing may be effectively performed in pressurized conditions by using an internal pressure device such as an autoclave. When annealing, the pressure may be in the range of about 14.7 psi (1 atm) to about 600 psi (40.8 atm).
[0042] After the annealing is performed, the inorganic salt is removed by separating, washing and drying the resultant, thereby completing the preparation of the nano phosphors.
[0043] The luminescent efficiency of the nano phosphors may be increased by performing additional post-annealing. The post-annealing may be at a temperature in the range of about 800° C. to about 1500° C. The time required for the post-annealing may be in the range of about 10 minutes to about 5 hours.
[0044] FIG. 1 illustrates the mechanism of removing defects of yttrium borate-based nano phosphors, according to an embodiment of the present invention. Yttrium borate nanoparticles, prepared using a low-temperature synthesis technique, may have surface and crystalline defects. The yttrium borate nanoparticles are mixed with an inorganic salt, and annealing is performed on the mixture, thereby compensating for the defects. Thus, nano phosphors having high crystalline properties may be obtained.
[0045] The nano phosphors may be used in a flat panel display such as a plasma display panel (PDP). The performance of the flat panel display is affected by the shape and crystalline properties of particles of the nano phosphors. In addition, since vacuum ultraviolet rays are absorbed into an ultrathin portion (having a thickness in the range of about 100 nm to 200 nm) of the particles of the nano phosphors, the surface properties of the nano phosphors importantly affects the luminescent efficiency of a display device such as a PDP that uses vacuum ultraviolet rays as an excitation source. On the other hand, phosphors prepared using a solid state reaction technique such as milling or pulverization operation have irregular shapes and many defects, and as a result, fail to obtain high luminescent efficiency and high resolution in a PDP.
[0046] According to an embodiment of the present invention, since nano phosphors having high crystalline properties may be prepared, when the nano phosphors are used in a PDP, high luminescent efficiency and high resolution of the PDP may be achieved. In addition, since the nano phosphors are approximately spherical in shape and have regular particle sizes as illustrated in FIG. 3 , high packing density may be obtained in a display device. In addition, the scattering of generated visible rays may be reduced, thereby increasing screen brightness and obtaining high resolution for the display device.
[0047] The present invention will now be described in more detail with reference to the following examples. However, these examples are for illustrative purposes only and are not intended to limit the scope of the present invention.
Example 1
Preparation According to an Embodiment of the Present Invention
[0048] 2.681 g of Y(NO 3 ) 3 .6H 2 O, 0.428 g of Eu(NO 3 ) 3 .5H 2 O, 1.210 g of H 3 BO 3 , 0.903 g of Gd(NO 3 ) 3 .6H 2 O, and 2.523 g of NH 2 CONH 2 , which are precursors, were prepared and dissolved in diethylene glycol. (Y,Gd)BO 3 :Eu nanoparticles having an average particle size of about 200 nm were synthesized by radiating microwaves having a frequency of 2.45 MHz into 500 ml of the resultant solution for 10 minutes at a power of 800 W. Then, the (Y,Gd)BO 3 :Eu nanoparticles were separated by a centrifugal separator, washed by distilled water, and then dried.
[0049] A solution in which 0.05 mol/liter of NaBO 2 dissolved in distilled water was prepared, and then the (Y,Gd)BO 3 :Eu nanoparticles were dispersed in the solution. Microwaves having a frequency of 2.45 GHz were radiated into the solution for 20 minutes in pressurized conditions of 40 atm at a power of 800 W. After the pressurized microwave annealing was performed, NaBO 2 that did not react was removed by separating, washing and drying the resultant, and then annealing was performed for 1 hour at 900° C. under an oxidation condition, thereby completing the preparation of (Y 0.7 ,Gd 0.2 )BO 3 :(Eu 3+ ) 0.1 nano phosphors having a size of about 200 nm.
Comparative Example 1
Prepared According to Another Process
[0050] 2.681 g of Y(NO 3 ) 3 .6H 2 O, 0.428 g of Eu(NO 3 ) 3 .5H 2 O, 1.210 g of H 3 BO 3 , 0.903 g of Gd(NO 3 ) 3 .6H 2 O, and 2.523 g of NH 2 CONH 2 , which are precursors, were prepared, and dissolved in diethylene glycol. (Y,Gd)BO 3 :Eu nanoparticles having an average particle size of about 200 nm were synthesized by radiating microwaves having a frequency of 2.45 MHz into 500 ml of the resultant solution for 10 minutes at a power of 800 W. Then, the (Y,Gd)BO 3 :Eu nanoparticles were separated by a centrifugal separator, washed by water, and then dried.
[0051] Obtained Y(Gd)—B—O:Eu nanoparticles were annealed for 1 hour at 900° C. under an oxidation condition, thereby completing the preparation of (Y 0.7 ,Gd 0.2 )BO 3 :(Eu 3+ ) 0.1 .
[0052] Turning now to FIGS. 2 and 3 , FIG. 2 is a graph of a result of X-Ray Diffraction (XRD) of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to Example 1 and FIG. 3 is a scanning electron microscopy (SEM) image of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to Example 1. Referring to FIGS. 2 and 3 , it may be seen that nanoparticles having a regular size of about 200 nm were synthesized.
[0053] FIG. 4A is an emission photoluminescence (PL) graph of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to Example 1 and measured at an excitation wavelength of 254 nm. FIG. 4B is a PL graph of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to Example 1 and measured at an excitation wavelength of 147 nm of vacuum ultraviolet rays. In FIG. 4B , the (Y,Gd)BO 3 :Eu nano phosphors were measured in the arrangement of a thin film. FIG. 5A is a PL graph of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to Example 1 and measured at an excitation wavelength of 254 nm. FIG. 5B is a PL graph of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to the Comparative Example 1 and measured at an excitation wavelength of 254 nm. Referring to FIGS. 4A through 5B , it may be seen that the (Y,Gd)BO 3 :Eu nano phosphors prepared according to Example 1 has an increased PL.
[0054] FIGS. 6A and 6B are a transmission electron Microscopy (TEM) image and a fast Fourier transform (FFT) diffractogram image respectively of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to the process of Example 1. FIGS. 7A and 7B are a TEM image and a FFT image respectively of the (Y,Gd)BO 3 :Eu nano phosphors prepared according to the process of the Comparative Example 1.
[0055] It may be seen from FIGS. 6A , 6 B, 7 A and 7 B that the (Y,Gd)BO 3 :Eu nano phosphors prepared according to the process of the Comparative Example 1 have defects of irregular particles, however the (Y,Gd)BO 3 :Eu nano phosphors prepared according to the process of Example 1 have almost no defects and have high crystalline properties. That is, referring to FIG. 6A , a regular lattice shape is shown, which means that an entire particle is of a single phase, that is, a single crystal. When a particle is composed of a single crystal instead of agglomerated crystals, the particle has excellent crystalline properties. FIG. 6B is a diffractogram of FIG. 6A . Referring to FIG. 6B , it may be seen that white spots are regularly arranged. Thus, it may be concluded that a single crystal particle of FIG. 6B was synthesized according to the process of Example 1. However, referring to FIGS. 7A and 7B , a single crystal particle was not synthesized when prepared according to the process of the Comparative Example 1. In addition, since white spots are not regularly arranged in the diffractogram of FIG. 7B , it may be concluded that particles with defects were synthesized instead of a single crystal.
[0056] While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A nano phosphor prepared by mixing a metal oxide nanoparticle and inorganic salt, a method of preparing the nano phosphor, and a display device including the nano phosphor. The method includes dissolving the inorganic salt in a solvent, adding the metal oxide nanoparticles to the solution, and annealing the resultant mixture, preferably under pressure. Such a process removes defects in the crystal structure of the nano phosphor, resulting in improved luminescent efficiency when incorporated into a display device. | 2 |
RELATED APPLICATION(S)
This application is a Divisional of U.S. application Ser. No. 10/050,752 filed Jan. 16, 2002 which claims benefit of U.S. Application No. 60/314,810 filed on Aug. 24, 2001. These applications are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to a system and method for accomplishing two-factor authentication using the internet.
BACKGROUND OF THE INVENTION
More and more, access to computer networks, web sites and the like is controlled by some type of security procedure. User names and passwords are commonly required for access to sensitive information at web sites. This provides a level of security, but can be breached by several relatively easy means, such as observance of a user or interception of the login signals as they are transmitted over the network or internet.
Token-based security is used typically for employee access to private networks. A token is a non-predictable code derived from both private and public information. The code is unique for each use. Thus, observation or interception of a token code is useless to the party intercepting the code, because by definition the code will not be used a second time. However, anyone who possesses the token generating software or device, by definition has access to the token codes. Thus, token-based security is dependent on possession of or access to software or a token-generating device, and so this security can be fairly easily breached.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a two-factor authentication system and method that uses the internet as the communications medium.
It is a further object of this invention to provide such a system and method that provides an additional layer of security to protect against online identity fraud.
It is a further object of this invention to provide such a system and method that reduces the risk of security breaches from password cracking.
It is a further object of this invention to provide such a system and method that allows a third party to provide additional online security to communications between a consumer and a business over the internet.
If is a further object of this invention to provide such a system and method that allows the consumer to have more control over internet-based security.
This invention results from the realization that increased internet communications security can be accomplished using two-factor authentication in which the user communicates authentication data for both authentication methods to a web site using the internet, and that web site then communicates with another web site to complete the authentication process.
In one embodiment of the invention, a hardware or software token is employed to accomplish one authentication method. The method is preferably accomplished across multiple secure web sites. Users enter data relating to one authentication method (e.g., their username and password). Users also enter data relating to the other authentication method.
For the token-based system, users are provided a token. Once users activate their token, they are required to use the token to authenticate (login) at the web site where the token was activated. A third field can be added to the username and password login page, so that a user can enter the one-time code generated by the token.
The first web site authenticates the user using one authentication method, for example the username and password. The second web site authenticates the user using the second authentication method. In one embodiment, once the first web site successfully authenticates the user using the first authentication method, the first web site transmits to the second web site over the internet user identification data, and the user-entered data relating to the second authentication method. For example, the first web site can transmit the username, the token code and a clientID to the second enabling web site for further authentication. At the second site, the user is authenticated using the second authentication method (e.g., the token). Authentication results are then returned from the second web site to the login web site, which admits or denies entry to the user based on the results of the two authentications.
Broadly, the invention comprises a method of accomplishing two-factor user authentication. The method contemplates the provision of two separate user authentication methods. A user is enabled to communicate authentication data for both authentication methods to a first web site, preferably using the intern et. At least some of the authentication data are communicated using the internet from the first web site to a second web site. Both web sites are involved in user authentication using the authentication data. Preferably, the second authentication method is one which can be used across multiple web sites that support the method, although it is possible to have a unique method (e.g., a one-time passcode) for each web site to be accessed by the user.
The first web site may initially authenticate the user based on the data relating to one of the authentication methods. The second web site may complete user authentication based on the data relating to the other authentication method. The first web site may communicate with the second web site only if the user is initially authenticated. The first web site may communicate to the second web site at least user-identification data, and data relating to the other authentication method.
One authentication method may employ a password. One authentication method may employ a token. The token may be hardware-based, and generate a code that comprises at least some of the data for the authentication method. The token may be a stand-alone, portable hardware device. The token may be embedded in a device such as a cell phone or a personal computer. The token may be USB-based and accessed by a browser. The token may be software-based, and generate a code that comprises at least some of the data for the authentication method. The software token may comprise a browser plug-in.
The second authentication method may comprise a one-time passcode, in some fashion. The one-time passcode can be generated by a hardware token, a piece of stand-alone software (the software token), or a piece of embedded software in a cell-phone or a USB device. However, the second authentication method does not have to be one-time. For example, the PIN used with a bank card is not a one-time PIN.
PKI (Public Key Infrastructure) can be used as the second authentication method as well. The public keys (one per user) would be stored on a server at one of the involved web sites, and the user would login with username-password. An encrypted or signed message would then be sent to the web site using the user's private key. The server would decrypt the message and would OK users who were successfully decrypted. In order to handle this scheme, the first web site would have to have means to receive encrypted messages and then to send them to the second web site for decryption. As an implementation issue, this is more complicated, but conceptually it is within the same idea.
The second authentication method may comprise a one-time passcode, in some fashion. Examples include the following:
1. Fixed simple codes such as a PIN that can be looked up in a database. 2. Fixed complex codes (PKI). Use public key to decrypt privately encrypted message. 3. One-time codes (e.g., a token). Requires a seed value which the token has and the web servers have, and a common algorithm used by the token and the server to generate the next item in a sequence, starting from the seed. 4. Complex, one-time codes. For example, encrypt the token code using PKI, and then decrypt it. This would protect against race attacks, where someone would monitor the network, intercept the one-time pass code, block the code from getting to the web site, then use the code from another browser. If the token code is encrypted with PKI, this cannot be done.
In another embodiment, the invention comprises a method of implementing token-based electronic security across multiple secure web sites, in which the user has a security token, the inventive method comprising storing unique token identification information, and the seed value of each token, in a security system; requiring the user, upon login to a secure web site, to enter at least the code generated by the user's token; passing the user's token code from the web site to the security system; using the security system to verify whether or not the user's token code was generated by the user's token; and passing the verification information from the security system to the web site, for use in web site security.
The requiring step may further require the user to enter a user name and user password. The method may further comprise the step of the web site verifying the user name and user password before passing the user's token code to the security system.
This invention in one embodiment features a method of implementing token-based electronic security across multiple secure web sites, in which the user has a security token, comprising storing unique token identification information, and the seed value of each token, in a security system, requiring the user, upon login to a secure web site, to enter at least the code generated by the user's token, passing the user's token code from the web site to the security system, using the security system to verify whether or not the user's token code was generated by the user's token, and passing the verification information from the security system to the web site, for use in web site security.
The requiring step may further require the user to enter a user name and user password. This method may further comprise the step of the web site verifying the user name and user password before passing to the security system the user's token code.
Featured in another embodiment of the invention is a method of accomplishing two-factor user authentication, comprising providing two separate user authentication methods, enabling a user to communicate authentication data for both authentication methods to a first web site using the internet, enabling the communication of at least some of the authentication data from the first web site to a second web site using the internet, wherein both web sites are involved in user authentication using the authentication data.
In this method, the first web site may initially authenticate the user based on the data relating to one of the authentication methods. The first web site may initially authenticate the user based on the data relating to one of the authentication methods. The second web site may complete user authentication based on the data relating to the other authentication method. The first web site may communicate with the second web site only if the user is initially authenticated. The first web site may communicate to the second web site at least data relating to the other authentication method, and user-identification data.
In this method, one authentication method may employ a password, and one authentication method may employ a token. The token may be hardware-based, and generate a code that comprises at least some of the data for the authentication method. The token may be a stand-alone, portable device. The token may be USB-based, and accessed by a browser. The token may be software-based, and generate a code that comprises at least some of the data for the authentication method. The token may comprise a browser plug-in.
One authentication method may employ a fixed complex code. The fixed complex code may comprise a public key infrastructure. In one embodiment, one authentication method is software-based. At least one user authentication method can be used across multiple web sites. The token may be embedded in a device such as a cell phone.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects features and advantages will occur to those skilled in the art from the following description of the preferred embodiment, and the accompanying drawings, in which:
FIG. 1 is a schematic high-level diagram of the system for this invention;
FIG. 2 is a flow chart of the preferred login process for the invention;
FIG. 3 is a flow chart of the preferred overall authentication process for the invention;
FIG. 4 is a more detailed flow chart of the client side authentication object of the authentication process of FIG. 3 ;
FIG. 5 is a more detailed flow chart of the server side authentication object of the authentication process of FIG. 3 ;
FIG. 6 is a more detailed flow chart of the authentication ISAPI extension object of the authentication process of FIG. 3 ;
FIG. 7 is a more detailed flow chart of the authentication COM functionality object of the authentication process of FIG. 3 ; and
FIG. 8 is a more detailed flow chart of the token code authentication object of the authentication process of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention may be accomplished in a method of accomplishing two-factor user authentication over the internet. Two separate user authentication methods are provided. In the preferred embodiment, one method uses a user name and password system, and the other method uses a token-based system. See FIG. 1 for a schematic diagram of a system that can accomplish the invention. The user 12 is required to communicate authentication data for both authentication methods to a first web site 14 using the internet 12 . Typically, this web site is the web site of a business with which the user is communicating. An example would be a brokerage account.
One of the authentication methods is accomplished at the first web site 14 . Typically, this comprises verification based on the user name and password. The first web site 14 then communicates at least some of the authentication data to the second web site 16 , also using the internet 12 . For the preferred embodiment, the first web site 14 would transmit to the second web site 16 the token code and an identification of the user resulting from the first authentication method. The second web site 16 would then accomplish the second authentication method to complete authentication of the user. The second web site 16 would then transmit back to the first web site 14 the results of the second authentication, so that the first web site 14 could then accept or deny access to the user.
The following are definitions of several terms used below:
FiPass Authentication Service provided by FiPass Inc. (the assignee herein) FSS FiPass Secured Site—Any site using the FiPass services and which conforms to certain guidelines. FiPass Token A ‘key ring’ sized device similar to a car alarm controller. The token is an existing network security device that produces a unique code each time it is used. End User A customer that utilizes the FiPass Authentication system at any FSS Billed User An End User who is responsible for the cost of the FiPass Authentication System Pre-Paid User An End User who is not responsible for the monthly charge or the shipping charge of the initial FiPass token FiPass Code The code produced by the FiPass token when the user presses the button, used to authenticate FiPass Users. FiPass Web Site The software located at www.fipass.com, which is the public FiPass, Inc. web site. The FiPass Web Site includes pages that allow FiPass Users to change their personal information. FiPass Server The software component located at secure.fipass.com, used for the FiPass Authentication System. FiPass Client The software component located at the FSS used to collect FiPass User information and to communicate that information with the FiPass Server. Can be in form of a COM object or JAVA Bean or other server side code (pert . . . ), also can run on any platform that can communicate over HTTPS. Billing The Software component used by FiPass to communicate with the Credit Card processor. Fulfillment The Software component used by FiPass to communicate with the token fulfillment provider, to package and ship tokens to end users.
System Features:
System Features Supported:
The inventive FiPass system will support the following Solution Model Use Cases. The description also details the methodology in this invention that accomplishes the preferred token-based security for the second authentication method.
Action Description 1. Online service network The FiPass client software administrator and must be installed on the FiPass admin setup FSS web site and the FSS service. must be enabled at FiPass. 2. End User enrolls in The End User decides to FiPass. utilize the FiPass authen- tication system and enrolls by filling out an online form. 3. FSS performs a batch Any FSS may choose to enrollment of underwrite the FIPass multiple End Users. authentication system and enroll multiple users at once. 4. End User receives After an End User successfully confirmation email enrolls with FiPass, an email along with confir- with a confirmation number is mation number. sent to the End User. 5. End User is flagged End user is set to receive a for Fulfillment. new token in the mail. 6. FiPass network admin- When tokens are fulfilled, the istrator adds tokens token serial numbers along to FiPass database. with the seed value for each SN must be entered in the database. 7. End User receives the After the enrollment process token in the mail. is completed, the End User receives the token in the mail. 8. End User activates Once the token has been token. received, it must be activated before it can be used. 9. End User activates Once enrolled with FiPass at token at another FSS one FSS, tokens may be used at any FSS where End Users have accounts. 10. End User activates After an End User receives a replacement token replacement token, it is activated at www.fipass.com. 11. FSS software modi- FSS database must be modified fieds Und User's to show that the End User is login requirements. required to login using the FiPass authentication system. 12. End User authenticates After the End User activates using FiPass system. the token, authentication takes place using the inventive FiPass system. 13. End User modifies An End User can modify personal information personal information such at FiPass com. as Billing Address, etc. 14. FiPass corrects The FiPass system attempts to mandatory billing correct failed charges that failure are considered mandatory. 15. FiPass CSR assists An End User can receive a an End User. defective token or need help in using the FiPass system; the CSR is there to provide assistance. 16. FiPass CSR request If a billing process fails alternative billing while the user is on the phone info after failure of with a CSR, the CSR will a discretionary request alternative billing charge. info. 17. FiPass CSR request If a billing process fails alternative billing while the user is on the phone info after failure of with a CSR, the CSR will a mandatory charge. request alternative billing info. 18. End User loses FiPass If an End User loses a token, Token. it will need to be replaced. 19. FiPass bills users FiPass bills users for the for the FiPass FiPass Authentication Service, Authentication as well as shipping costs and Service. replacement token fees (if applicable). 20. End User deactivates The End User can deactivate the FiPass authenti- the FiPass system at any FSS cation system at a while it is still activated particular FSS. at another FSS. 21. End User cancels the The End User can cancel the FiPass authentication FiPass system if all his or system. her FSS accounts have been deactivated. 22. FiPass Management gets For business analysis purposes, reports. FiPass management needs to get reports on web site usage and the growth in FiPass accounts. 23. User Returns Defective If users receive a defective Token token or the token become inoperable, it will need to be replaced. 24. User Reinstates If user's account has been cancelled account cancelled due to a billing failure and was unaware of the failed charge, the account can be reinstated.
Authentication
Two-factor authentication is the main piece of the inventive system and method. Authentication takes place at both the FSS client side and server side, as well as at FiPass. FIGS. 2 and 3 detail the preferred authentication process. The user enters in his/her username, password, and one-time pass code in the login form at the FSS. Client side script validates the data entered and then the information is submitted to the FSS. The FSS authenticates the user using the username and password. Once the FSS has determined that the password belongs to that user, the FSS then determines if the user requires FiPass for further authentication. If so, the FSS formats the data in XML and posts that data to Secure.FiPass.com. An ISAPI extension is installed on the web servers, which receives the request for authentication and parses the XML and passes it to the business object. The business object determines the token SN by passing the user's username to a stored procedure which looks it up in the user database. The token SN and the one-time pass code are passed to the authentication object, SWAuthenticate.dll, to authenticate the user. The SWAuthenticate.dll object wraps the functionality of the libswecapi2.dll, which has all the functionality needed to access the SW DB for authenticating. SWAuthenticate.dll utilizes all that functionality and is abled to be called from other objects that can make use of that functionality for the authentication process.
The separate objects required for authentication are listed just below, and further described below.
Client Side Authentication FSS Server Side Authentication FiPassExt.dll?Authenticate FiPassCOM.dll SWAuthenticate.dll
Client Side Authentication (See FIG. 4 )
Authentication begins when users log in at the FSS. Users enter their username, password and one-time pass code into the log in form and click the submit button. When the button is clicked, client side java script executes validating the data. If any data is invalid, the form is not submitted and the cursor is located on the field with invalid data. Valid data is submitted to the FSS where the FSS Server Side Authentication takes place and returns the user to the log in form if any data is invalid.
FSS Server Side Authentication (see FIG. 5 )
When the user has successfully entered in valid data in the log in form at the FSS, the FSS will also validate the data entered by the user similar to the client side script. The FSS then authenticates the user using their normal method (username and password). Once the FSS authenticates the user, the FSS then checks if the user requires FiPass. If no FiPass is required then the user proceeds into the web site. However, if FiPass is required for the user, the FSS formats the username, one-time pass code and ClientID in XML and posts it to Secure.FiPass.com. The data is then posted using 1 parameter
1. authenticationinfo
for example,
https://secure.fipass.com/agents/fipassext.dll?Authentication?authentication info=<?xml version=1.0 standalone=yes?><authenticationinfo> . . . .
After the data is sent to Secure.FiPass.com, the FSS will wait for the results in the form of a response from Secure.FiPass.com.
FiPassExt.dll?Authenticate
The authentication data that is received by Secure.FiPass.com is in the form of 1 parameter using a name value pairs and is sent using the standard HTTP ‘post’ method. An ISAPI extension (see FIG. 6 ) is installed on the web servers, which receive the requests. In order to receive specific fields and field types, the ISAPI extension must know what fields it is going to receive and their variable types. This is done in the command-parsing map, located in a file that is generated by the wizard. The following lines must be added in order to receive the specific parameters sent by the FSS:
ON_PARSE_COMMAND(Authenticate, FiPassExtension, ITS_PSTR)
ON_PARSE_COMMAND_PARAMS(“AuthenticateInfo”)
The first line tells IIS and the ISAPI extension (the class FiPassExtension) the “Authenticate” function is to be executed when a request has been received and 2 parameters of type integer and string will be sent in the request. The second line defines the parameter names that will be sent as part of the request.
Once the data is received from the FSS, it must be checked for validity before further processing. If the data is not in a valid form, then a response specifying the invalid data will be sent to the FSS immediately and no other processing will take place. The Authenticate method does this validation, along with calling the business object, FiPassCOM.Authenticate to authenticate the user.
When the FSS makes a request to Secure.Fipass.com, IIS first receives that request and then calls the Authenticate function that exists in the FiPassExt.dll extension. IIS passes the function a pointer to CHTTPServerContext and the XML string that was sent by the FSS. The pointer is used to communicate back and forth with IIS, which communicates back and forth with the FSS. In the ISAPI extension, the function declaration has 2 parameters, a pointer to the CHTTPServerContext, so it can communicate back to IIS after the processing is completed, and the XML parameter sent from the FSS.
Below is a list of requirements for this function.
To parse the XML that is received After parsing, each XML tag set that holds a piece of required data is checked for blank values If any required fields are blank, an error code is immediately returned to the FSS and no further processing will take place. If all fields are valid, the Authentication object (located in FiPassCOM.dll) is called and is passed the XML string received from the FSS The Authentication object performs its task (see FiPassCOM.dll and returns its results (pass or fail) to the ISAPI extension and IIS, who passes it back to the FSS
FiPassCOM.dll (see FIG. 7 )
When requests are made to Secure.FiPass.com for authentication, the ISAPI extensions validate the data and pass off the valid XML to business objects, which carry out the request. FiPassCOM.dll holds all the objects, which carry out all the requests FSS′ can make. Each object is in the form of a class within the FiPassCOM.dll. Each class has a specific task. The authentication functionality will take place in the Authentication class. The Authentication class contains the method called Authenticate, which requires the following functionality.
Receive XML string from ISAPI extensions. Parse XML and set local variables Call SP_GetLoginbyAlias and pass it the username and ClientID, which is used to retrieve the token SN to be used to authenticate the user The result from SP_GetLoginbyAlias is returned to the Authentication object which then calls SWAuthenticate to do the authentication The results from SWAuthenticate are returned back to the Authentication object (FiPassCOM.dll) which passes it back to the ISAPI extension and IIS, who passes it back to the FSS
All requests made by an FSS will utilize the user database. The FiPassCOM.dll object handles all user database access depending on the request. Using the MS ADO object, stored procedures are executed, which are compiled and running inside the database process.
SWAuthenticate.dll (see FIG. 8 )
The object used to communicate with the SW DB is SWAuthenticate.dll. This object wraps the functionality that is required to access the SW DB and authenticate users. It is called from the business objects and always receives 2 strings, the token SN and the one-time pass code, and returns one string, which is either pass or fail.
Other embodiments will occur to those skilled in the art and are within the scope of the claims. | A method of accomplishing two-factor user authentication, comprising providing two separate user authentication methods, enabling a user to communicate authentication data for both authentication methods to a first web site using the internet, and enabling the communication of at least some of the authentication data from the first web site to a second web site also using the internet. Both web sites are thus involved in user authentication using the authentication data. | 7 |
This application is a divisional of prior U.S. Ser. No. 10/123,488, filed Apr. 16, 2002 now U.S. Pat. No. 6,802,856, which is a continuation of U.S. Ser. No. 09/852,226, filed May 8, 2001, now U.S. Pat. No. 6,371,978 issued Apr. 16, 2002, which is a divisional of U.S. Ser. No. 09/459,004 filed Dec. 10, 1999, now U.S. Pat. No. 6,254,593 issued Jul. 3, 2001.
BACKGROUND OF THE INVENTION
The invention relates to a stent delivery system for use at a bifurcation and, more particularly, a bifurcated stent delivery system having a retractable sheath.
Stents conventionally repair blood vessels that are diseased. Stents are generally hollow and cylindrical in shape and have terminal ends that are generally perpendicular to their longitudinal axes. In use, the conventional stent is positioned at the diseased area of a vessel and, after placement, the stent provides an unobstructed pathway for blood flow.
Repair of vessels that are diseased at a bifurcation is particularly challenging since the stent must overlay the entire diseased area at the bifurcation, yet not itself compromise blood flow. Therefore, the stent must, without compromising blood flow, overlay the entire circumference of the ostium to a diseased portion and extend to a point within and beyond the diseased portion. Where the stent does not overlay the entire circumference of the ostium to the diseased portion, the stent fails to completely repair the bifurcated vessel. Where the stent overlays the entire circumference of the ostium to the diseased portion, yet extends into the junction comprising the bifurcation, the diseased area is repaired, but blood flow may be compromised in other portions of the bifurcation. Unopposed stent elements may promote lumen compromise during neointimalization and healing, producing restenosis and requiring further procedures. Moreover, by extending into the junction comprising the bifurcation, the stent may block access to portions of the bifurcated vessel that require performance of further interventional procedures. Similar problems are encountered when vessels are diseased at their angled origin from the aorta as in the ostium of a right coronary or a vein graft. In this circumstance, a stent overlaying the entire circumference of the ostium extends back into the aorta, creating problems, including those for repeat catheter access to the vessel involved in further interventional procedures.
Conventional stents are designed to repair areas of blood vessels that are removed from bifurcations and, since a conventional stent generally terminates at right angles to its longitudinal axis, the use of conventional stents in the region of a vessel bifurcation may result in blocking blood flow of a side branch or fail to repair the bifurcation to the fullest extent necessary. The conventional stent might be placed so that a portion of the stent extends into the pathway of blood flow to a side branch of the bifurcation or extend so far as to completely cover the path of blood flow in a side branch. The conventional stent might alternatively be placed proximal to, but not entirely overlaying, the circumference of the ostium to the diseased portion. Such a position of the conventional stent results in a bifurcation that is not completely repaired. The only conceivable situation in which the conventional stent, having right-angled terminal ends, could be placed where the entire circumference of the ostium is repaired without compromising blood flow, is where the bifurcation is formed of right angles. In such scenarios, extremely precise positioning of the conventional stent is required. This extremely precise positioning of the conventional stent may result with the right-angled terminal ends of the conventional stent overlaying the entire circumference of the ostium to the diseased portion without extending into a side branch, thereby completely repairing the right-angled bifurcation.
To circumvent or overcome the problems and limitations associated with conventional stents in the context of repairing diseased bifurcated vessels, a stent that consistently overlays the entire circumference of the ostium to a diseased portion, yet does not extend into the junction comprising the bifurcation, may be employed. Such a stent would have the advantage of completely repairing the vessel at the bifurcation without obstructing blood flow in other portions of the bifurcation. In addition, such a stent would allow access to all portions of the bifurcated vessel should further interventional treatment be necessary. In a situation involving disease in the origin of an angulated aorto-ostial vessel, such a stent would have the advantage of completely repairing the vessel origin without protruding into the aorta or complicating repeat access.
In addition to the problems encountered by using the prior art stents to treat bifurcations, the delivery platform for implanting such stents has presented numerous problems. For example, a conventional stent is implanted in the main vessel so that a portion of the stent is across the side branch, so that stenting of the side branch must occur through the main-vessel stent struts. In this method, commonly referred to in the art as the “monoclonal antibody” approach, the main-vessel stent struts must be spread apart to form an opening to the side branch vessel and then a catheter with a stent is delivered through the opening. The cell to be spread apart must be randomly and blindly selected by recrossing the deployed stent with a wire. The drawback with this approach is there is no way to determine or guarantee that the main-vessel stent struts are properly oriented with respect to the side branch or that the appropriate cell has been selected by the wire for dilatation. The aperture created often does not provide a clear opening and creates a major distortion in the surrounding stent struts. There is no way to tell if the main-vessel stent struts have been properly oriented and spread apart to provide a clear opening for stenting the side branch vessel.
In another prior art method for treating bifurcated vessels, commonly referred to as the “Culotte technique,” the side branch vessel is first stented so that the stent protrudes into the main vessel. A dilatation is then performed in the main vessel to open and stretch the stent struts extending across the lumen from the side branch vessel. Thereafter, the main-vessel stent is implanted so that its proximal end overlaps with the side branch vessel. One of the drawbacks of this approach is that the orientation of the stent elements protruding from the side branch vessel into the main vessel is completely random. Furthermore, the deployed stent must be recrossed with a wire blindly and arbitrarily selecting a particular stent cell. When dilating the main vessel stretching the stent struts is therefore random, leaving the possibility of restricted access, incomplete lumen dilatation, and major stent distortion.
In another prior art device and method of implanting stents, a “T” stent procedure includes implanting a stent in the side branch ostium of the bifurcation followed by stenting the main vessel across the side branch ostium. In another prior art procedure, known as “kissing” stents, a stent is implanted in the main vessel with a side branch stent partially extending into the main vessel creating a double-barreled lumen of the two stents in the main vessel proximal to the bifurcation. Another prior art approach includes a so-called “trouser legs and seat” approach, which includes implanting three stents, one stent in the side branch vessel, a second stent in a distal portion of the main vessel, and a third stent, or a proximal stent, in the main vessel just proximal to the bifurcation.
All of the foregoing stent deployment assemblies suffer from the same problems and limitations. Typically, there are uncovered intimal surface segments on the main vessel and side branch vessels between the stented segments. An uncovered flap or fold in the intima or plaque will invite a “snowplow” effect, representing a substantial risk for subacute thrombosis, and the increased risk of the development of restenosis. Further, where portions of the stent are left unopposed within the lumen, the risk for subacute thrombosis or the development of restenosis again is increased. The prior art stents and delivery assemblies for treating bifurcations are difficult to use, making successful placement nearly impossible. Further, even where placement has been successful, the side branch vessel can be “jailed” or covered so that there is impaired access to the stented area for subsequent intervention.
Attempts to bring any device, such as a bifurcated stent on a bifurcated balloon assembly, to a bifurcation over two wires are prone to the problem of wire wrapping. This phenomenon involves one wire crossing the other first anteriorly then posteriorly. The resulting wrapping then creates resistance to advancement of the device, thus resulting in failure of deployment. Therefore, when delivering a device ultimately utilizing two wires, it would be desirable to first track the device in over a single wire, thus avoiding wire wrapping. The present invention offers a solution to these problems and others.
As used herein, the terms “proximal,” “proximally,” and “proximal direction” when used with respect to the invention are intended to mean moving away from or out of the patient, and the terms “distal,” “distally,” and “distal direction” when used with respect to the invention are intended to mean moving toward or into the patient. These definitions will apply with reference to apparatus, such as catheters, guide wires, stents, the like. When used with reference to body lumens, such as blood vessels and the like, the terms “proximal,” “proximally,” and “proximal direction” are intended to mean toward the heart; and the terms “distal,” “distally,” and “distal direction” are intended to mean away from the heart, and particularly with respect to a bifurcated blood vessel, are intended to mean in the direction in which the branching occurs.
SUMMARY OF THE INVENTION
The invention provides for a bifurcated stent delivery system having a retractable sheath. The system is designed for repairing a main vessel and a side branch vessel forming a bifurcation, without compromising blood flow in other portions of the bifurcation, thereby allowing access to all portions of the bifurcated vessel should further interventional treatment be necessary. The catheter and the retractable sheath are designed to reduce the likelihood of wire wrapping during the stenting procedure.
In one aspect of the invention, there is provided a stent delivery assembly for treating bifurcated vessels including a dual balloon Y-shaped catheter. The catheter includes a first expandable member and a second expandable member. A first guide wire lumen is provided for receiving a first guide wire. The first guide wire lumen extends through at least a portion of the catheter including the first expandable member. A second guide wire lumen is provided for receiving a second guide wire, the second guide wire lumen extends through at least a portion of the catheter including the second expandable member. A tubular member is provided, wherein the first expandable member and the second expandable member are normally biased apart, but are restrained and held together by the tubular member to provide a low profile during delivery of a Y-shaped stent.
In another aspect of the invention, a method is provided of stenting a bifurcated vessel having a bifurcation, a first vessel branch, and a second vessel branch. The method includes the step of providing a dual balloon Y-shaped catheter having a first expandable member and a second expandable member. A Y-shaped stent is mounted on the first and second expandable members. A tubular member is placed about the first and second expandable members such that the first and second expandable members are normally biased apart, but are restrained and held together by the tubular member. The Y-shaped stent is then delivered to a target area. The tubular member is withdrawn proximally until the first expandable member and the second expandable member are released and spring apart. The Y-shaped stent is next implanted by inflating the first and second expandable members. The first and second expandable members are then deflated and the catheter is withdrawn.
In yet another aspect of the invention, a method is provided of stenting a bifurcated vessel having a bifurcation, a first vessel branch, and a second vessel branch. The method includes the step of providing a dual balloon Y-shaped catheter including a first expandable member and a second expandable member. A first guide wire lumen is provided for receiving a first guide wire. The first guide wire lumen extends through at least a portion of the catheter including the first expandable member. A second guide wire lumen is provided for receiving a second guide wire. The second guide wire lumen extends through at least a portion of the catheter including the second expandable member. A Y-shaped stent is mounted on the first and second expandable members. A tubular member is placed about the first and second expandable members such that the first and second expandable members are normally biased apart, but are restrained and held together by the tubular member. A second guide wire is positioned distally of the bifurcation in the first vessel branch. The second guide wire is then backloaded into the second guide wire lumen. Next, the catheter and tubular member are advanced over the second guide wire so that the catheter is advanced distally of the bifurcation in the first vessel branch. Alternatively, the catheter can be advanced proximally of the bifurcation in the first vessel branch. The tubular member is withdrawn proximally until the first expandable member and the second expandable member are released and spring apart. Next, the catheter is withdrawn proximally to a position proximal of the bifurcation. A first guide wire is provided and advanced out of the first guide wire lumen and into the second vessel branch distally of the bifurcation. The catheter is advanced distally over the first and second guide wires until the Y-shaped stent is positioned at the bifurcation. The Y-shaped stent is then implanted by inflating the first and second expandable members. The first and second expandable members are deflated and the catheter and guide wires are withdrawn.
Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a bifurcation in which a prior art “T” stent is in a side branch ostium followed by the stenting of the main vessel across the branch ostium.
FIG. 2 is an elevational view of a bifurcation in which “touching” prior art stents are depicted in which one stent is implanted in the side branch, a second stent implanted in a distal portion of the main vessel next to the branch stent, with interrupted placement of a third stent implanted more proximally in the main vessel.
FIG. 3 is an elevational view of a bifurcation depicting “kissing” stents where a portion of one stent is implanted in both the side branch and the main vessel and adjacent to a second stent implanted in the main vessel creating a double-barreled lumen in the main vessel proximal to the bifurcation.
FIG. 4 is an elevational view of a prior art “trouser legs and seat” stenting approach depicting one stent implanted in the side branch vessel, a second stent implanted in a proximal portion of the main vessel, and a close deployment of a third stent distal to the bifurcation leaving a small gap between the three stents of an uncovered lumenal area.
FIG. 5A is an elevational view of a bifurcation in which a prior art stent is implanted in the side branch vessel.
FIG. 5B is an elevational view of a bifurcation in which a prior art stent is implanted in the side branch vessel, with the proximal end of the stent extending into the main vessel.
FIG. 6 is an elevational view, partially in section, depicting an embodiment in which a Y-shaped catheter assembly deploys a Y-shaped stent in a bifurcation.
FIG. 7 is an elevational view depicting the Y-shaped catheter assembly of FIG. 6 in which the stent is mounted on the expandable members of the catheter.
FIG. 8 is a perspective view of the assembly of FIG. 7 shown partially inserted into the sheath.
FIG. 9 is an elevational view, partially in section, of a bifurcation in which the catheter of FIG. 7 is delivering the stent in the bifurcated area with the catheter inserted into the sheath.
FIG. 10 is an elevational view, partially in section, of a bifurcation in which the catheter of FIG. 7 is delivering the stent in the bifurcated area with the sheath being withdrawn proximally.
FIG. 11 is an elevational view, partially in section, of a bifurcation in which the catheter of FIG. 7 has been withdrawn proximally of the bifurcation and a guide wire is being extended into the second vessel branch.
FIG. 12 is an elevational view, partially in section, of a bifurcation in which the catheter of FIG. 7 is implanted at the bifurcation.
FIG. 13 is another embodiment of the dual balloon Y-shaped catheter.
FIG. 14 is an elevational view, partially in section, of the dual balloon Y-shaped catheter of FIG. 13 restrained by the sheath.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in the exemplary drawings wherein like reference numerals indicate like or corresponding elements among the figures, the present invention includes a bifurcated stent delivery system for treating bifurcated vessels in, for example, the coronary arteries, veins, arteries, and other vessels in the body.
Prior art attempts at implanting intravascular stents in a bifurcation have proved less than satisfactory. For example, FIGS. 1-4 depict prior art devices which include multiple stents being implanted in both the main vessel and a side branch vessel. In FIG. 1 , a prior art “T” stent is implanted such that a first stent is implanted in the side branch near the ostium of the bifurcation, and a second stent is implanted in the main vessel, across the side branch ostium. With this approach, portions of the side branch vessel are left uncovered, and blood flow to the side branch vessel must necessarily pass through the main vessel stent, causing possible obstructions or thrombosis.
Referring to FIG. 2 , three prior art stents are required to stent the bifurcation. In FIG. 3 , the prior art method includes implanting two stents side by side, such that one tent extends into the side branch vessel and the main vessel, and the second stent is implanted in the main vessel. This results in a double-barreled lumen which can present problems such as thrombosis, and turbulence in blood flow. Referring to the FIG. 4 prior art device, a first stent is implanted in the side branch vessel, a second stent is implanted in a proximal portion of the main vessel, and a third stent is implanted distal to the bifurcation, thereby leaving a small gap between the stents and an uncovered lumenal area.
Referring to FIGS. 5A and 5B , a prior art stent is configured for deployment in side branch vessel 5 . In treating side branch vessel 5 , if a prior art stent is used, a condition as depicted will occur. That is, a stent deployed in side branch vessel 5 will leave a portion of the side branch vessel exposed, or as depicted in 5 B, a portion of the stent will extend into main vessel 6 .
Turning to FIGS. 6-12 , in one embodiment of the present invention, stent delivery assembly 10 is provided for treating bifurcated vessels. In this embodiment, a Y-shaped stent is implanted to cover the bifurcation. Catheter 12 can be configured as a dual balloon Y-shaped catheter having a proximal end and a distal end. The catheter includes first expandable member 14 and second expandable member 16 that are configured to reside side-by-side (Y-shaped) for low profile delivery and to spring apart for implanting Y-shaped stent 18 . Each of the expandable members has a proximal end and a distal end. The stent is removably mounted on the first and second expandable members.
A first guide wire lumen 20 is provided for receiving first guide wire 22 . The first guide wire lumen extends through at least a portion of catheter 12 including first expandable member 14 . A second guide wire lumen 24 is provided for receiving second guide wire 26 . The second guide wire lumen extends through at least a portion of the catheter including second expandable member 16 . The expandable members can be inflatable non-distensible balloons. The guide wires 22 , 26 preferably are stiff wires each having a diameter of 0.014 inch, but can have different diameters and degrees of stiffness as required for a particular application. A particularly suitable guide wire can include those manufactured and sold under the tradenames Sport® and Ironman®, manufactured by Advanced Cardiovascular Systems, Incorporated, Santa Clara, Calif.
A tubular member, such as sheath 28 , is provided, wherein the first expandable member and the second expandable member are normally biased apart, but are restrained and held together by the sheath to provide a low profile during delivery of Y-shaped stent 18 . The sheath can be formed from a polymer such as polyethylene, polyurethane, and nylons, although other similar polymeric material may also be suitable, such as polyetheretherketone (PEEK), polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), and the like. Other suitable materials can be used as are known to those skilled in the art.
The catheter 12 further includes an inflation lumen (not shown) for inflating first and second expandable members 14 , 16 simultaneously. The expandable members can be inflated by delivering a suitable inflation media, such as saline, to the expandable members via the inflation lumen. In one embodiment, the second expandable member is longer than the first expandable member so that distal portion 30 of the second expandable member protrudes from sheath 28 during delivery to facilitate tracking.
In one method of stenting a bifurcated vessel, as shown in FIGS. 9-12 , Y-shaped stent 18 is mounted on first and second expandable members 14 , 16 . The second guide wire 26 is positioned distal of the bifurcation in first vessel branch 6 . The second guide wire is then back loaded into second guide wire lumen 24 . The catheter 12 and sheath 28 are advanced over the second guide wire so that the catheter is advanced distally of the bifurcation in the first vessel branch. During the advancement of the catheter, the first and second expandable members are restrained and held together by sheath. Consequently, the sheath helps to provide a low profile during delivery of the stent.
In keeping with the invention, sheath 28 is withdrawn proximally until first expandable member 14 and second expandable member 16 are released and spring apart. The catheter 12 is then withdrawn proximally to a position proximal of the bifurcation. In one embodiment, first guide wire 22 has been contained as an integrated guide wire within first guide wire lumen 20 up to this point. Alternatively, the first guide wire may be inserted into tile proximal end of the first guide wire lumen at this time. The first guide wire is then advanced out of the first guide wire lumen and into second vessel branch 5 distally of the bifurcation.
If, after withdrawal of the sheath to release the expandable members, the device is seen to be oriented such that first expandable member 14 is further away from vessel 5 than is second expandable member 16 , it may be desirable to withdraw second guide wire 26 and readvance it into vessel 5 with first guide wire 22 then advanced into vessel 6 . This reassignment of wires permits avoidance of rotation of more than 90 degrees. In situations in which there is concern about recrossing of the lumen of the side branch vessel with either wire, this wire reassignment is performed before catheter 12 is withdrawn proximal to the bifurcation.
The Y-shaped stent 18 is implanted by advancing distally over first and second guide wires 22 , 26 until the stent is positioned at the bifurcation in apposition with carina 32 . Due to the appropriate wire selection, rotation of no more than 90 degrees will be required. The stent is implanted by inflating first and second expandable members 14 , 16 , which are designed to inflate simultaneously. Then the first and second expandable members are deflated and the catheter and guide wires can be withdrawn from the patient's vasculature. The novel arrangement of sheath 28 and guide wires 22 , 26 and their respective lumens permit single unit transport of a Y-shaped stent to the distal target site without wire wrapping problems and it allows for minimal requirements of rotation of the device (less than 90 degrees) for optimal deployment (allowing minimal twist deformity).
In a related method, Y-shaped stent 18 is mounted on first and second expandable members 14 , 16 . The second guide wire 26 is positioned distal of the bifurcation in first vessel branch 6 . The second guide wire is then back loaded into second guide wire lumen 24 . The catheter 12 and sheath 28 are advanced over the second guide wire so that the catheter is advanced proximally of the bifurcation in the first vessel branch. During the advancement of the catheter, the first and second expandable members are restrained and held together by the sheath. Consequently, the sheath helps to provide a low profile during delivery of the stent.
In keeping with the invention, sheath 28 is withdrawn proximally until first expandable member 14 and second expandable member 16 are released and spring apart. In one embodiment, first guide wire 22 has been contained as an integrated guide wire within first guide wire lumen 20 up to this point. Alternatively, the first guide wire may be inserted into the proximal end of the first guide wire lumen at this time. The first guide wire is then advanced out of the first guide wire lumen and into second vessel branch 5 distally of the bifurcation.
Next, catheter is advanced distally over first and second guide wires 22 , 26 until Y-shaped stent 18 is positioned at the bifurcation in apposition with carina 32 . Due to the appropriate wire selection, rotation of no more than 90 degrees will be required. The stent is implanted by inflating first and second expandable members 14 , 16 , which are designed to inflate simultaneously. Then the first and second expandable members are deflated and the catheter and guide wires can be withdrawn from the patient's vasculature. The novel arrangement of sheath 28 and guide wires 22 , 26 and their respective lumens permit single unit transport of a Y-shaped stent to the distal target site without wire wrapping problems and it allows for minimal requirements of rotation of the device (less than 90 degrees) for optimal deployment (allowing minimal twist deformity).
Notably, it is contemplated that the methods of the present invention can be accomplished with any suitable catheter 12 . Referring to FIGS. 13 and 14 , another embodiment of the dual balloon Y-shaped catheter is depicted. The catheter has first stem 40 and second stem 42 . The first stem 40 is connected to first expandable member 14 . The second stem 42 is connected to second expandable member 16 having distal portion 30 for tracking. In this embodiment, the second expandable member is approximately twice as long as the first expandable member; however, it is contemplated that the expandable members can be of varying lengths. The expandable members can be simultaneously inflated via an inflation lumen (not shown). The first guide wire 22 is positioned within the first expandable member and the second guide wire is positioned within the second expandable member. The first and second expandable members are normally biased apart, but are restrained and held together by sheath 28 to provide a low profile during delivery of Y-shaped stent 18 .
While the invention herein has been illustrated and described in terms of a catheter assembly and method of use, it will be apparent to those skilled in the art that the invention can be used in other instances. Other modifications and improvements may be made without departing from the scope of the invention. | An improved catheter assembly and method are provided for treating bifurcated vessels. The catheter assembly of the present invention includes a tubular sheath for restraining dual balloons normally biased apart. Withdrawal of the sheath allows the balloons to separate and deploy intravascular stents in a bifurcated vessel. The catheter assembly also includes the feature of containing two guide wire lumens in a single catheter designed to track over a single wire prior to arrival at the bifurcation, thus preventing wire wrapping and crossing of the wires. | 0 |
This is a continuation of application Ser. No. 878,332, filed Feb. 16, 1978, now abandoned, which was a continuation of Ser. No. 718,804, filed Sept. 1, 1976, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to energy input control systems, and in particular, to a condensate sensing and control system for preventing formation of condensation on a unit being monitored.
Examples of prior art techniques for detecting moisture content of the air, e.g., dew point, or relative humidity, and/or for controlling formation of condensate on surfaces being monitored are disclosed in U.S. Pat. Nos. 2,435,895; 2,687,035; 2,720,107; 2,733,549; 2,733,607; 2,904,,995; 2,975,638; 3,142,986; 3,293,901; 3,161,056; 3,166,928; 3,195,344; 3,195,345; 3,287,974; 3,416,356; 3,422,677; 3,460,352; 3,552,186; 3,599,862; 3,696,360; 3,859,502; and British Pat. No. 900,194. Continuously heating such components is not desirable because the heated surfaces may appear warm to the touch, and because that approach involves a substantial waste of energy. It has been recognized that it is only necessary to heat the exposed surfaces being monitored periodically to keep them sufficiently warm in view of existing conditions to prevent the formation of moisture and frost.
The necessity to selectively and intermittently control a variety of electrical loads often presents significant problems. For example, commercial refrigerated units, e.g., refrigerators and freezers, particularly commercial upright units located in retail stores, are typically enclosed with by glass doors with the products contained therein visible to the consumer.
Typically, metal framed glass doors are used in these units. From the retailers point of view, it is necessary to prevent formation of condensate on these units, not only for aesthetic reasons, but more importantly because condensate, e.g., moisture and/or frost, reduces visibility through the glass doors and, reduces sales.
To overcome this problem, a number of techniques have been utilized for heating the exposed portions of the refrigerated unit e.g., the door frame, the mullion, and/or the glass itself to preclude the formation of condensate.
A number of techniques have been developed for intermittently heating the exposed surfaces of refrigerated units in an attempt to prevent the formation of condensate and to keep the surface temperatures of the glass, the door frame, the outer frame, and the mullions just above that point at which formation of condensate commences. Some of these techniques include presetting a heater to operate intermittently, but according to the fixed cycle. Another approach is to sense the relative humidity in the room in which the unit is disposed and to turn on the heaters when the relative humidity exceeds a preselected value. However, formation of condensate on the surfaces of refrigerated units is a function not only of the relative humidity in the room, but also of the temperature in the room and of the temperature of the exposed surfaces of the units, said surface temperature being partially determined by the temperature within the refrigerated units. Sensing relative humidity alone does not provide sufficient information to minimize energy utilization while simultaneously precluding formation of moisture.
Another approach is to adjust the duty cycle of the heater manually. While this may suffice, it requires constant monitoring by store personnel since the formation of frost can vary as a function of the number of times the doors are opened and as a function of changes in ambient conditions. It is common, therefore, for such systems to be set at a level to insure prevention of frost on the unit under the worst conditions, resulting in wasted energy.
As a variation of the relative humidity sensors, there are systems which adjust the duty cycle as a function of the relative humidity-increasing the duty cycle of the heaters as relative humidity increases. Again, since the point at which condensate forms is a function of more than the relative humidity in the ambient atmosphere, such systems are often adjusted to operate with a longer duty cycle than is necessary in order to preclude formation of condensate.
One of the patents identified above, U.S. Pat No. 3,696,360, discloses an alarm for warning of impending condensation on an element being monitored. While the system disclosed in this system is designed to be responsive to the various conditions which affect formation of condensation, it is believed the circuit disclosed, which includes a sensor and a load would not provide the sensitivity or accuracy required to insure prevention formation of condensation at minimum energy levels. The sensor being in the same circuit as the load, the required safety for use in areas where the sensor is exposed to personnel is not present.
In order to properly insure against formation of condensate on the exposed surfaces of a refrigerated unit, any control system should utilize as input information all of the factors which determine the point at which condensate forms on the exposed surfaces of the unit. The factors that determine this point are the ambient temperature in the room, the ambient relative humidity and the temperature of the exposed surfaces of the unit being monitored. Any satisfactory system should be reliable, automatic, efficient, should effect operation of the heaters for the minimum amount of time necessary to prevent formation of condensate, and must be safe.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a control system for controlling input energy to a load such as electric heaters connected to portions of a refrigerated unit, or other units where ambient conditions on opposite sides of a thermal barrier differ, which is responsive to all of the conditions which affect the formation of condensate on the surfaces being monitored.
A system in accordance with the present invention incorporates a sensor affixed to an exposed surface of the refrigerated unit, the sensor being responsive to the temperature of the surface, to the ambient temperature and to ambient relative humidity for initiating energization of the heaters to prevent formation of condensation on the surfaces of the refrigerator unit being monitored. When the sensor is exposed, it is also necessary, for safety purposes, that the sensor be electrically isolated so that inadvertent contact between personnel and the sensor cannot result in an unsafe condition.
The energy control system of the present invention provides a transducer or sensor suitably located to monitor the exposed surfaces of a refrigerated unit. The sensor is electrically isolated from the power circuit connected to electric heaters, and accurately and reliably detects the point at which condensate forms on the unit and controls operation of heaters to prevent formation of condensation on the exposed surfaces being monitored.
More specifically, a variable resistive element is affixed to the exposed surfaces of a refrigerated unit in a manner that the temperature of the variable resistor exposed to ambient conditions varies in accordance with the temperature of the exposed surfaces of the unit. Thus, moisture on the surface of the sensor can be indicative of the conditions on the surfaces of the unit being monitored, and may be utilized to control operation of heaters to maintain the unit surfaces at a temperature just above that at which condensate forms with a minimum expenditure of energy.
In accordance with the present invention, the sensor includes a plurality of exposed spaced apart conductors embedded in an electrically insulated body which, in turn, is mounted on a thermally conductive member suitably affixed to or mounted on a surface of the unit. A signal is applied across the resistive element, the resistance of which varies in accordance with the amount of moisture on its surface, moisture altering the conductivity between the spaced conductors. A peak detector circuit is connected to the variable resistance transducer to produce a signal having an amplitude representative of the peak signal across the transducer which, in turn, varies as a function of the resistance of the transducer.
Since the resistance of the transducer varies as a function of the moisture formation on its surface, the detected signal has an amplitude which varies in accordance with the monitored condition, i.e., the incipient formation of condensate. This detection signal is applied to one input of a differential amplifier which produces an output of selected magnitude when the difference between the detection signal and a constant reference signal reaches a preselected magnitude.
This control output is terminated when the difference between the detection signal and the reference signal drops to a value less than the value required in initiate the output by a selected amount. The control output energizes a light emitting diode for producing a coupling signal.
A photo transistor is responsive to the light emitted by the light emitting diode to produce a switching signal in response to those emissions which is applied to the control electrode of an electronic switching element connected in series between a source of energy and a load being controlled. When monitoring a refrigerated unit, the load may be a plurality of resistance heaters appropriately located to raise the temperature of the exposed surfaces to preclude formation of condensate on those surfaces.
When the temperature of the exposed surfaces rises, in response to energization of the heaters, above the temperature at which moisture forms, the temperature of the sensor also rises causing moisture to evaporate from its surface. The resulting increase in the resistance of the sensor terminates the control output.
Emissions from the light emitting diode terminate, the switching signal from the phototransistor terminates and the signal applied to the control electrode of the switching element is thus ended. The switching element opens and the heaters one deenergized until the incipient formation of condensate is again detected on the surface of the sensor.
A system in accordance with the present invention provides efficient, accurate and reliable monitoring of the condensate formation or other conditions to be monitored, utilizes the minimum amount of energy necessary to maintain the desired condition, and at the same time provides the necessary safety by isolating the exposed sensor to prevent electrical hazards.
Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and of one embodiment thereof, from the claims and from the accompanying drawing in which each and every detail shown in fully and completely disclosed as a part of this specification in whch like numerals refer to like parts.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a refrigerated unit with which the system of the present invention may be used;
FIG. 2 is a perspective view of a sensor assembly for use in the system of the present invention; and
FIG. 3 is a circuit diagram of a system incorporating the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail one specific embodiment, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated. The scope of the invention will be pointed out in the appended claims.
FIG. 1 illustrates the front of refrigerated unit 10 incorporating a pair of door assemblies 12 mounted side by side in the unit 10 to provide a large area for the display and viewing of merchandise contained in the unit 10. Each door assembly 12 comprises a stationary mounting frame 14 and a pair of pull doors 16, adapted to close the opening in the stationary frame 14. Each of the doors 16 is of the type which includes a metal frame 18 in which a transparent panel 20 is mounted so that merchandise in the refrigerated unit will be clearly visible to customers. Typically, the transparent panel 20 is made of glass. The frame 14 of the unit, the door frame 18, the transparent glass panel 20 and other surfaces of the unit, e.g., mullions, are typically heated by resistive heaters to preclude the formation of condensate thereon.
The input control system of the present invention when used in conjunction with a refrigerated unit such as the type shown in FIG. 1 monitors the conditions at exposed surfaces of the unit and controls operation of electric heaters to preclude formation of condensate on such surfaces while utilizing the minimum amount of energy required to accomplish that purpose.
A system incorporating the present invention, incorporates a sensor assembly 25, shown in FIG. 2. The sensor assembly 25 includes a thermally conductive support plate 30 which is affixed to an exposed surface of the refrigerated unit, e.g., to the mullion at 32 in FIG. 1, and is maintained in surface to surface contact therewith. The support plate 30 may be affixed to the mullion 32 by metallic fasteners such as screws (not shown) which pass through the apertures 34 in the support plate 32 into the mullion to insure maximum thermal conductivity between the plate 32 and that portion of the refrigerated unit 10 to which it is affixed. In one embodiment, the support plate is made of aluminum, is approximately one inch square and 1/32 inch thick.
The sensor unit 35 is affixed to the surface of the support plate 32. The sensor unit 35 comprises an electrically insulative disk 36 which in the illustrated embodiment is a 1/32 inch thick epoxy glass disc. A pair of spaced conductors 38, 40 are formed on the surface of the disc 36 which, in the illustrated embodiment, include interleaved generally circular conductive fingers 38a, 40a spaced apart from each other and electroplated with an anticorrosive conductive element such as nickel plate and with a low contact resistance material such as gold.
In the illustrated embodiment, the insulated support disc 36 affixed to the support plate 30 is a 1/32 inch thick epoxy glass disc on which is photoprinted a one-half ounce copper pattern defining the spaced contacts 38, 40. The surface of the copper 4 is electroplated with a 0.00005 inch anti-corrosive layer of nickel plate which is electroplated with a 0.00003 inch thick low contact resistance layer of gold.
The sensor 35 forms part of the input control system shown in FIG. 3. The system of FIG. 3 includes a source 48 of ac potential, typically a 110 volt ac power line. The system includes a sensing circuit 50 and a switching circuit 52 responsive to operation of the sensing circuit 50 for operating an electronic switch 54 to connect a load 56, e.g., the resistive heaters, directly to the ac power source 48.
Since the control system of the present invention controls the energization of the load 56 by selectively connecting it directly to a 110 volt source 48 and since the sensor 35 which forms a part of the control system is located on exposed surfaces of a refrigerated unit which is being monitored, an electrical shock hazard could exist unless the system including the sensor 35 is isolated both from the load 56 and from the source 48. Isolation is further beneficial in that the energizing and deenergizing of the load does not affect the performance of the system in sensing incipient formation of condensation and precluding formation of condensation on the unit being monitored.
Accordingly, both the sensing circuit 50 and the switching circuit 52 are coupled to the power source 48 through isolating step down transformers 58, 60, respectively, the primaries of which are connected across the ac source 48. The secondary of the sensing circuit transformer 58 produces a twelve 25 mA output which is applied across a voltage divider consisting of the resistive sensor 35 and a second resistor 62 connected in series across the secondary of the sensing circuit transformer 58. This secondary voltage is also applied across a rectifier 64 and filter capacitor 66 to produce a d.c. control voltage and reference voltage. The junction between the resistive sensor 35 and the voltage divider resistor 62 is connected to the plus input of an operational amplifier 68.
The output of amplifier 68 is fed back to the negative input of amplifier 68 through rectifier 70. The operational amplifier 68 acts as a peak detector and produces a dc output which is integrated by capacitor 72 and resistor 74 and is applied through an input resistor 76 to the positive terminal of a second operational amplifier 78 which acts as a differential amplifier. The other input to the differential amplifier 78 is connected to the junction of a pair of voltage divider resistors 80, 82. The output of the differential amplifier is fed back to the positive input through a feedback resistor 84.
When the resistance of the resistive sensor 35 drops to a selected value, as determined by the value of the input voltage divider resistor 62 to the peak detector amplifier 68, the output of the peak detector will exceed the reference voltage sufficiently to cause the differential amplifier to produce an output signal 85. This output is applied to a light emitting diode (LED) 86 which produces light emission in response to this signal.
When the resistance of the sensor 35 rises as moisture evaporates from the surface thereof, the differential amplifier 78 terminates its signal when the level of the output of the peak detector 68 achieves a second value lower than the amplitude which initiated the output signal. This hysteresis characteristic minimizes continuous system oscillation. Resistors 87a and 87b acts as a voltage divider to insure that the LED turns off in the absence of signal 85. The value selected for discontinuing the output signal 85 is such as to deenergize the load 56, when desired, i.e., turn off the electric heaters when they have been on sufficiently long to insure the refrigerated unit has reached a temperature that precludes formation of condensate.
The switching circuit 52 includes the switching transformer 60, the secondary of which produces of 4.5 volt 250 mA signal rectified in a full wave receifier 88 and filtered by a filter capacitor 90 as is well known. The rectified output provides a source of power for a phototransistor circuit including phototransistor 92 and resistors 93 and 94 and for an amplifier circuit 95 which includes a pair of transistors 96, 97 and resistors 98, 99 connected to the output of the phototransistor 92. The phototransistor 92 produces a signal at its emitter in response to light emitted by the LED 86 which signal is amplified by the amplifier circuit 95. The output 100 of the amplifier circuit 95 is applied to a gate electrode of the electronic switch 54, a triac. A capacitor 101 is connected across the gate electrode to minimize transients.
The main electrodes of the triac 54 are connected in series with the power source 48 and the load 56. The triac 54 closes in response to the output 100 of the switching amplifier 95 in response to emissions from the LED 86. The optical coupling between the sensing circuit 50 and the switching circuit 52 isolates the sensor 35 from the load 56 to positively insure safety and insure that the sensor may in no way be connected across the 110 volt line.
A manual switch 102 may be connected across the triac 54 for the purpose of testing and manual operation of the heaters when desired.
In operation, when condensate begins to form on the surface of the sensor 35, the resistance between the pair of spaced electrodes drops, until, in the illustrated embodiment, the resistance achieves a level of 2 meg-ohms ±5%. The amplitude of the output of the peak detector 68 increases to cause the differential amplifier 78 to produce a signal 85 which energizes the LED 86.
The phototransistor 92 responds to the light emitted by the LED 86 to produce a signal amplified in the switching amplifier 95 to close the triac switch 54 and energize the load 56.
As the surface of the refrigerated unit begins to rise, so does the temperature of the sensor 35. Moisture evaporates from the surface of the sensor 35 causing an increase in its resistance thereby reducing the amplitude of the output of the peak detector 68. When the resistance of the sensor increases sufficiently, the amplitude of the output of the peak detector 68 drops to a value which terminates the signal 85 produced by the differential amplifier 78 to deenergize the LED 86, thereby terminating the output of the phototransistor 92 and causing the triac switch 54 to open. The load 56 is deenergized. Formation of condensate has been precluded. The load remains deenergized until such time as the condensate again begins to form on the surface of the sensor 35 causing its resistance to drop to a value sufficiently low to trigger the system once again.
Thus there has been disclosed a condition responsive input control system for sensing a condition to be monitored, for providing a switching signal to control a load related to that condition in which the sensor, the sensing circuit and the switching circuit are all isolated from the load and from any power source required to operate the load. The system in accordance with the present invention is safe, accurate, reliable, simple and self-contained, and is adapted to be automatically responsive to a variety of factors which may effect the condition to which the system is designed to respond.
In the circuit shown in FIG. 3, the following components have been used satisfactorily:
______________________________________Diode 64 - IN4006Bridge 88 - each IN4006Diode 70 - IN4446Capacitor 66 220uf 25vCapacitor 72 1uf 25vCapacitor 90 1000uf 10vCapacitor 102 0.05uf 10vResistor 62 2 meg ohm 1%Resistor 74 2 meg ohmResistor 76 47 k ohmResistor 80 100 k ohm 1%Resistor 82 100 k ohm 1%Resistor 84 2 meg ohmResistor 87a 15 k ohmResistor 87b 2 k ohmResistor 93 270 ohmResistor 94 10 meg ohmResistor 98 100 ohmResistor 99 10 ohm 1 wattOperational Amplifiers 68, 78 - each 1/2 LM1458LED 86 and phototransistor 92 - OPI5000Triac 54 - SPT225Transistors 96 and 97 - 2N3569______________________________________
From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the true spirit and scope of the novel concept of the invention. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. | An input control system having a sensing circuit, a switching circuit and a source of power isolated from the sensing circuit and the switching circuit. The sensing circuit includes a sensor having a variable electrical characteristic, a detector for detecting variations in that characteristic and for producing a representative output, a signal producing circuit for producing a predetermined signal in response to the detector output achieving a selected value, and coupler responsive to the predetermined signal to produce a coupling output. The switching circuit which is isolated from the sensing circuit produces a switching signal in response to the coupling signal to operate a switch for connecting an electrical load to the power source. | 5 |
BACKGROUND OF THE INVENTION
This invention relates in general to a method and apparatus for building, and more particularly to a method and apparatus for creating concrete forms for reinforced insulated concrete walls.
In most prior art systems for making concrete walls, sheets of rigid material generally treated to enhance the ability to release from a set concrete surface, are disposed in a parallel relationship with some form of spacing hardware attached to the panels in order to maintain the appropriate spacing. Usually, the hardware includes waler's brackets, for supporting a waler to lend strengthing properties to the forms. Many types of waler brackets are described in the prior art including U.S. Pat. Nos. 3,547,398 (Furr, et al., 12/15/1970); 3,426,992 (Buyken, 10/11/1967); 3,729,159 (Foster, (4/24/1973); 3,241,803 (Foy, 3/22/1966); 4,054,259 (Johnson, 10/18/1977); 3,730,476 (Prichard, 5/1/1973); 3,599,929 (Holley, et al., 8/17/1971); 3,286,976 (Lynch, 11/22/1966); 3,462,107 (Buyken, 8/19/1969); 3,462,108 (Buyken, 8/19/1969); and 3,347,510 (Buyken, 10/17/1967).
One of the disadvantages of the waler brackets described in the prior art is that they are not designed to join together adjacent form panels, but rather are to be placed towards the center of the form panels, thus requiring additional hardware to join panels together. Another disadvantage is that they are unsuitable for use with insulation material which tends to have low stress bearing capabilities.
Additionally, in most construction systems walls are first formed and insulation material is then installed by skilled laborers thereby increasing the overall costs of the system.
SUMMARY OF THE INVENTION
Cost savings can be achieved by forming a concrete wall directly on an insulation panel. The method of the present invention contemplates creating a concrete form by placing reinforced sheets of insulating material parallel to form panels. The sheets of insulating material are separated by a spacing device and the concrete is poured directly on the form created. After the concrete is set the form panels are removed and the sheets of insulating material remain in place.
The spacing device includes a spacing member disposed between the substantially parallel sheets of insulating material and form panels. The spacing member is engaged from the exterior portion of the form panels and sheets of insulating material by T-shaped screws. The spacing member is provided with a tapered bracket that engages the reinforced borders of the sheets of insulating material so that as the spacing member is compressed against the sheets of insulating material, the tapered bracket forces adjacent sheets of insulating material to come together. The spacing member is also provided with tie holders which are adapted to engage the T-shaped screws and compress the sheets of insulating material and the form panels on the spacing member.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details are explained below with the help of the examples illustrated in the attached drawing in which:
FIG. 1 is a perspective view of an insulation module according to the present invention;
FIG. 2 is an end view of a pair of insulation modules disposed adjacent to one another;
FIG. 3 is a cut away view of the components of the wall forming system;
FIG. 4 is a view of the spacing device;
FIG. 5 is an alternative embodiment for the spacing device;
FIG. 6 is a perspective cut away view of a wall made in accordance with the method of the invention including window components;
FIG. 7 is a cross-sectional exploded view of a wall built in accordance with the invention; and
FIG. 8 is a cross-sectional view of a window sill built in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, the concrete wall form of the system of the present invention includes an insulation module 11. Typically the insulation module 11 is two feet wide by room height and its thickness may depend on the insulation qualities of the material. The insulation module 11 has an insulation panel 13 made of adequate insulation material such as styrofoam for example. Disposed adjacent to a surface 14 of the insulation panel 13 is reinforcing material 15 such as wire mesh. The reinforcing material, as is shown in FIG. 2, includes an offset distance 17 to maintain the reinforcing material away from the insulation panel surface 14. Adjacent to each lateral side of the insulation panel 13 is disposed a U-shaped cap 19 made of sheet metal, for example, which serves to secure the reinforcing material 14 to the insulation panel 13. Disposed in between adjacent U-shaped caps is a gasket 20 made of styrofoam or other suitable material.
The building system of the present invention contemplates, as shown in FIG. 3, the use of a reinforce concrete foundation 21 substantially in the form of a T beam. A U-shaped channel 23, which may be made of sheet metal is secured to one side of the base of the T foundation 21 or a floor slab, and is extended throughout the foundation. Immediately below the channel 23 is disposed an insulation plank 24 for the purpose of maintaining the insulation throughout the building.
Disposed on the channel are a plurality of insulation modules 11. Disposed to the other side of the base of the T are a plurality of form panels 24, which are typically made of plywood or other easily available construction material. Concrete is poured in the form made by the form panels 25 and insulation modules 25 and 11 respectively to create the wall 27. The side of the insulation module 11 opposite to the wall 27, corresponding to the inside of the building, may be finished by securing gypsum boards, or drywalls, to the U-shaped caps of the insulation module. This will result in a strong reinforced concrete structure with extremely efficient insulation built in, and a finished drywall interior wall surface.
In making the concrete forms from the insulation modules and form panels 11 and 23 respectively, a spacing device 32 shown in FIG. 4 is provided. The spacing device 32 includes a metal bracket 33 with a first perpendicularly projecting end piece 34 having a hole 35 thereon. The second end of the bracket 33 has a retaining end piece 37 having a width that is approximately the width of two adjoining U-shaped caps 19 plus the gasket 20. The retaining end piece 37 has a hole 38 at the center.
Also disposed on the second end of the bracket 33 are two projecting end portions 39 which are disposed a distance substantially equal to the width of two adjoining U-shaped caps 19, away from each other at the base. The two projecting sections 39 are outwardly tapered so that as the insulation panels 13 are pressed against the retaining end piece 37, the projecting members 39 force the two adjacent panels together by a cam-like action on the periphery of the U-shaped caps 19, thereby compressing the gasket 20. Disposed adjacent to the brackets and cooperating with the holes 35 and 38 is a central member 41 having internally threaded holes 42 at either end thereof. The central member 41 may be square and made of plastic material. Adjacent to the end 34 is disposed another spacing piece 45 having a hole 46 extended therethrough, which may be internally threaded. The spacing piece 45 has one end portion 47 with a substantially square cross section. A washer 51 is also provided with a square hole 53 disposed eccentrically on the washer and adapted to engage the end portion 47 of the spacing piece 45. The square hole 53 is off-center to provide a larger area of protrusion to engage another form panel 25. The other panel of type typical form panel 25, which is usually made of plywood, is provided with a notch 55 which is adapted to engage the square end portion 47 of the spacing piece 45. Disposed towards the exterior of the form panel 25 is a retainer piece 59 having a first portion 60 with a substantially U-shaped cross section and a second portion 61 substantially perpendicular thereto with a notch 62 thereon. The substantially U-shaped portion 60 has an end section 63 which is substantially curved towards the opening provided. Also provided is a T-shaped screw 65 having a threaded position 66 adapted to engage the internally threaded holes 42 and a cross member 69 adapted to engage the notch 62 on the second portion 61 of the retainer piece 59.
During the set-up stage the insulation modules 11 may be placed vertically one end to channel 23 which is provided in the foundation 21. The insulation modules 11 are joined together at the U-shaped caps 19 by the metal bracket 33. The projecting members 39 engage the insulation panels 13 and the two adjoining U-shaped caps 19. The T-shaped screw 65 may be set between the two adjoining sheet metal caps 19 and through the hole in the end piece 37 and into the central member 41. Because of the diameter of the T-shaped screw 65 a small space will be left between two joined insulation modules 11. In order to seal this space the gasket 20 is disposed between two adjacent U-shaped caps and may be glued to one side of one of the sheet metal caps thereby filling the void area. A retainer piece 59 is then pivoted about the cross member of the T-shaped screw 65 and forced downwardly so that the T-shaped screw 64 is put in tension with the retainer piece 59 and the two projecting ends 39 are compressed into the insulation panel and will pull together the U-shaped caps of the modules. Simultaneously gasket 20 will be compressed between the two U-shaped caps 19, thus locking the two panels together with a tight seal from the gasket 20.
As can be seen from the description above as the insulation modules are put in compression the projecting members 39 force the adjacent U-shaped caps 19 to come together and compress gasket 20 that that an adequate seal is provided between the two adjacent insulation modules 11.
The wall may then be built upwardly by placing another form panel 25 on top of the already existing form panel and a second layer of concrete forms is built around the perimeter of the wall (see, for example, FIG. 7). The second set of form panels 25 are locked in place by the compression provided by waler or cross beams 71. As the cross beams 71 is placed in the retainer piece 59 it will compress the form panel inwardly towards the washer 76 which will then hold the form panel in its proper place. Thereafter the T-shaped screw 65 are removed along with the retainer pieces 59 and then the exterior form panels 25 are removed. The result is a reinforced concrete wall connected to insulation palens. The exterior form panels 25 can be reused many times over, or later, for example, as roofing material. The retainer piece 59 can also be used to support walers or cross beams 71 which strengthen the insulation panels 13 to prevent deformation while the concrete is setting.
As can be seen in FIG. 5, an alternative embodiment may comprise an elongated central portion 73 having two internally threaded end portions 75 and 76 with an end bracket 79 having a width spanning the width of two adjoining U-shaped caps 19, and two projecting end portions 80 and 81 adapted to engage the adjoining U-shaped caps 19.
As can be seen in FIG. 7, the building procedure may be used without the use of the insulation modules 11. Rather two form panels 25 may be used and the wall may be built upwardly by placing a second set of form panels on top of the first set and locking them in place by waler or cross member 71. In this fashion a wall of any desired height may be built.
The versatility of the system is also evidenced in FIG. 8 which shows the use of the retainer piece 59 together with the waler 71 and a short form panel 82 to create a window sill 84.
The formation of windows in this construction can be provided by having specialized modules 83 of specific length, as shown in FIG. 8. There two shortened modules 85 and 86 are shown adjoining and supporting a window sub jamb 87, having a third transversly disposed insulation module 88 of reduced width disposed on top of the sub jamb 87. The window sub jamb 87 forms the opening in the walls and remains as a permanent part of the building. Most standard pre-finished window units may be secured to the sub jambs, thus completing the window unit. The width of the sub jamb 87 is substantially the same as the desired width of the wall, and as the concrete is poured the sub jamb 87 can be formed directly in place. Door jambs may be formed from the same single profiled stock shape as the window jambs and are connected in the same manner to the insulation moduals.
As can be appreciated by the detailed description of the invention so far, such a building system will offer an efficient way of building homes and other structures. All of the material can be pre-cut and modularized, and one need only connect the modules together. The system of erection is so simple that previous construction experience is not required due to the simplicity of the connection device. In addition, this type of construction will offer ideal insulation to the building. The insulation modules 11, which can be made of styrofoam may be provided with installed fixtures and fully wired thereby necessitating only to be connected to the main supply of electricity. A typical package to be offered to the builder would include building blue prints and specifications with numerous floor plans and exterior finishes to chose from, or one can design their own home plan due to the versatility of the module panel construction. A variety of exterior wall patterns can be available to chose from. Insulation modules 11 that will lock together to form the interior side of the building, with certain modules 11 having installed fixtures 100 fully wired inside the module, as shown in FIG. 6. All pre-wired fixtrues need only a finished flush face plate 102 to be secured to the installed fixtures after the drywall panels are installed to the U-shaped caps of the insulation modules. All pre-wiring is connected to a central conduit chase 101 above or in the ceiling area then to the main supply.
Metal door and window sub jambs 87 are designed to lock onto the insulation modules anywhere in the perimeter wall line desired. Both the window and door sub jambs are constructed from the same profiled stock and are designed to keep the concrete from incrouching upon their desired opening areas during the placement of the wet concrete. After the concrete has become hard, finished window units are secured to the sub window jambs, and the finished doors are hinged to the sub door jambs. Also to be provided are U-shaped channels 23 for the perimeter wall and to set the insulation modules 11 into the foundation 21. The form panel 25 can all be pre-cut from standard plywood sheets of four foot by eight foot into two foot by eight foot and be prepared with the notches 55 for connection to the insulation modules 11.
Also to be provided are all connecting hardware including spacing devices 32 for the form panels 25 to connect the insulation modules 11. The exterior of the wall may be patterned by providing thin plastic sheets or styrofoam panels with imprinted patterns so that when the concrete sets the pattern will be set thereby enhancing the outward appearance of the concrete wall. For example, the concrete wall can simulate concrete blocks or bricks on the exterior. Finished exterior doors will be provided and prepared with the hardware holes and hinged recesses.
The interior can be finished by attaching drywall gypsum boards 111 to the sheet metal caps 19 of the insulation moduals which may be purchased locally. All of the interior portion materials can be shipped to the job site by any supplier. The interior ceilings can also be covered with styrofoam insulation plank 113 secured to the under side of the roof rafters and then finished over with gypsum board.
Roof trusses can be provided or the specification can be sent to a local dealer to be fabricated and delivered to the job site. All wood members needed to complete the roof structure can be precut and need only to be nailed into place. If only one home is to be built from the exterior retaining form panels 25, then these panels can be reused as the sub-roofing material and be nailed to the trusses, thus reducing the cost of roof sheeting. Alternatively, the exterior retaining forms can be used many times over to form the exterior of the walls of other buildings before ultimately becoming the sub-roof to one. | A method and apparatus is disclosed for forming insulated walls by pouring concrete directly on a form made in part of insulating material which will remain in place after the concrete sets. An apparatus for spacing the sheets of insulating material from the sheets of other material to create a concrete form is also disclosed, which also provides the function of bringing adjacent sheets of insulating material to create an adequate seal for the concrete. A tie holder for supporting cross members is also disclosed. | 4 |
BACKGROUND
The invention relates to a power supply and a control method thereof, and more particularly to a power supply and a control method which can detect a power requirement of an electronic device and accordingly provide an output power thereto.
Currently, conventional power supplies provide a fixed output voltage or a manually-selectable output voltage according to output numbers of the power supplies.
FIG. 1 is a block diagram of a conventional power supply with a fixed output voltage. The power supply 1 coupled to an alternating current (AC) power source outputs direct current (DC) power to an electronic device 2 at a predetermined voltage by a transformer 11 and a rectifier 12 .
FIG. 2 is a block diagram of a conventional power supply with a plurality of selectable output voltages. The variable output power supply 3 is capable of providing different levels of output power to meet power requirements for various electronic devices. For example, a potential selector 32 can be manually switched to various voltage levels for the power requirements of the electronic device 20 , and thus the power supply outputs power at a selected potential to the electronic device 20 .
With manual determination or selection of output voltage, however, it is easy to erroneously execute and generate mismatched output voltage, potentially damaging the device. For example, a 5-volt output power from a power supply to an electronic device requiring power of 12 volts causes the electronic device to malfunction. Similarly, device damage, such as circuit burnout, occurs if 12 volts of power is provided to a 5-volt electronic device.
Thus, the invention is to prevent the mismatched output voltage arising from manual operation of the conventional power supply, thereby improving convenience and safety of utility.
SUMMARY
An aspect of the invention provides a power supply capable of detecting power requirements based on power information from an electronic device, and selecting an output power accordingly. A memory of the electronic device is used to store the information concerning the power requirements.
An embodiment of the power supply comprises a converter, a control device, and a switch. An output power generated from the power supply is transformed into an input power by means of the converter to be applied to an electronic device coupled to the power supply. The control device coupled to the converter accesses the power information concerning the power requirements of the electronic device, accordingly controls the converter to adjust the output power, and outputs a control signal after adjusting the output power. The switch is coupled to the converter and the control device to switch an output port of the power supply to the converter after receiving the control signal, thereby transferring the output power from the converter to the electronic device.
In the embodiment, the power supply is also capable of returning the output port of the power supply to its original state, for efficient processing of subsequent detections. Thus, the power supply further comprises a current detector to detect whether the output power is applied to the electronic device. The switch disconnects the converter from an output port of the power supply and couples the control device to the output port when the output power is not applied to the electronic device.
Another aspect of the invention also sets forth an electronic device to provide the power information to a power supply. The electronic device comprises a major circuit, an input port, a memory storing the power information, and a gate switch including a first gate device and a second gate device. The first gate device is coupled between the input port and the memory, and the second gate device is coupled between the input port and the major circuit.
When the voltage of the input port meets first requirements, the memory is coupled with the input port by means of the gate switch as the power information is read from the input port. When the voltage of the input port meets second requirements, the input port is coupled with the major circuit by means of the gate switch so that the power supply provides output power to the major circuit for normal operation.
Furthermore, another aspect of the invention provides a control method of the power supply. An electronic device is coupled to a power supply. An input power from an external power source is then converted into an output power. Power information from the electronic device is read. An adjusted output power is finally applied to the electronic device.
Thus, the power supply control method detects automatically the connected electronic device and outputs the appropriate adjusted power additionally, thus preventing problems arising from manual operation.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will become more fully understood by referring to the following detailed description and accompanying drawings, wherein:
FIG. 1 is a block diagram of a conventional fixed output power supply;
FIG. 2 is a block diagram of a conventional power supply with selectable output voltage;
FIG. 3 is a schematic diagram of a power supply of the invention;
FIG. 4A is a schematic diagram of an electronic device of the invention;
FIG. 4B is a diagram of the electronic device of FIG. 4A of the invention; and
FIG. 5 shows a flowchart of the power supply control method of the invention.
DETAILED DESCRIPTION
An aspect of the invention provides a power supply capable of detecting power requirements based on information from an electronic device, and selecting a power output accordingly.
FIG. 3 is a schematic diagram of a power supply of an embodiment of the invention. The power supply 4 comprises a converter 40 , a control device 50 , a switch 60 , and a current detector 70 . When an input port and an output port of the power supply 4 are coupled to an alternative power current (AC) power source and a electronic device 8 having a memory 80 , respectively, and a common node COM and a normally closed node N.C of the switch 60 are coupled to the output port of the power supply 4 and a detection node of the control device 50 , respectively, the control device 50 detects power information stored in the memory 80 via the switch 60 . The power information comprises a rated potential, a rated current, or a rated power, of the electronic device 8 .
In the present embodiment, the memory 80 is a non-volatile random access memory (NVRAM), and the switch 60 is an electrical or a mechanical switch such as a relay or an optical coupler.
When obtaining the power information, the control device 50 first controls the potential selector 42 to select an output power of a transformer 41 corresponding to the power information. The rectifier 43 rectifies and stabilizes the output power of the potential selector 42 , and then the control device 50 controls the switch 60 to change a passage from the normally closed node N.C to a normally opened node N.O. Thus, the converter 40 can provide an adjusted output power to the electronic device 8 via the switch 60 .
The power supply 4 further comprises a current detector 70 to detect whether the output power is applied to the electronic device 8 . Additionally, the current detector 70 can operate in coordination with the control device 50 to determine whether the power supply 4 unloads the electronic device 8 , whereby the passage of the switch 60 can be returned to it original state. For example, when the power supply 4 unloads the electronic device 8 , the current of the current detector 70 is zero, accordingly the control device 50 adjusts the passage of the switch 60 . Thus, the control device 50 can be coupled to the output port of the power supply 4 or returned to its original state.
In the present embodiment, the current detector 70 is a hall sensor or a magnetic sensor, and the power supply 4 is an AC/DC, AC/AC, DC/AC, or DC/DC mode power supply.
In FIG. 3 , if being coupled to an electronic device 8 without the memory 80 , the power supply 4 can be manually switched to provide a required power of the electronic device.
FIG. 4A is a schematic diagram of an electronic device of the invention. The electronic device 9 comprises a major circuit 90 , a memory 91 , and a gate switch 10 having a first gate device 92 and a second gate device 93 . When the electronic device 9 is coupled to the power supply 4 , the gate switch 10 determines whether the voltage of the input port Vin meets a first requirement or a second requirement. When the input port Vin is coupled to an output port of the control device 50 of FIG. 3 , the first gate device 92 is turned on and second gate device 93 is turned off, whereby the input port Vin can be coupled to the memory 91 . Hence, the power supply 4 can detect the power information stored in the memory 91 via the first gate device 91 . Additionally, if the power supply 4 provides the adjusted output power according to the power information, the first gate device 92 is turned off and the second gate device 93 is turned on, whereby the input port Vin can be coupled to the major circuit 90 . Hence, the power supply 4 can provide the adjusted output power to the major circuit 90 via the second gate device 93 .
FIG. 4B is a diagram of the electronic device of FIG. 4A of the invention. The first gate device 92 comprises resistors R 1 and R 2 and a first transistor 900 . The resistors R 1 and R 2 are connected in series and coupled between the input port Vin and reference node GND. The first transistor 900 is connected between the input port Vin and the memory 91 , and a gate electrode of the first transistor 900 is connected to the series point of the resistors R 1 and R 2 .
The second gate device 93 comprises a resistor RG, a second transistor 910 , a diode D, and a relay 920 . The resistor RG is connected between the input port Vin and the second transistor 910 . The diode D is coupled to a coil of the relay 920 in parallel, and coupled between the input port Vin and the second transistor 910 in series. The relay 920 is coupled to the input port Vin via the common node COM, and coupled to the major circuit 90 via the normally opened node N.O.
Suppose that the first transistor 900 is a depletion-type MOS transistor having a −4-volt threshold voltage, the second transistor 910 is an enhancement-type MOS transistor having a 4-volt threshold voltage, and the output power of the power supply 4 is between 0V to 24V. When the voltage of the input port Vin is less than 4V, according to a divided potential of the resistor R 1 , the reverse bias of the gate-source pole of the first transistor 910 is between 0V to −4V, which is greater than its threshold voltage −4V, thus the first transistor 900 operates in triode area or is turned on. At the same time, according to a divided potential of a resistor RG, the forward bias of the gate-source pole of the second transistor 910 is between 0V to 4V, which is less than its threshold voltage 4V, thus the second transistor 910 operates in cut-off state or is turned off.
When the voltage of the input port Vin is between 4V to 24V, the first transistor 900 operates in cut-off state or is turned off because the reverse bias is between −4V to −24V or less than its threshold voltage −4V. At the same time, the second transistor 910 operates in saturation state or is turned on because the forward bias is between 4V to 24V or greater than its threshold voltage 4V.
The first transistor 900 or the second transistor 910 can be replaced by JFET, which is switched by a bias of its gate-source pole.
Hence, the first transistor 900 and the second transistor 910 are controlled by a detecting signal and the output power from power supply 4 . When the voltage of the input port Vin equals to the detecting signal or is less than 4V, for example, the voltage of the input port Vin meets a first requirement, thus the first transistor 900 is turned on and the second transistor 910 is turned off. Additionally, when the voltage of the input port Vin equals to the output power or is greater than 4V, for example, the voltage of the input port Vin meets a second requirement, thus the first transistor 900 is turned off and the second transistor is turned on.
When the first transistor 900 is turned on, the detecting signal is provided to the memory 91 via the first transistor 90 , whereby the power supply 4 can obtain the power information. Furthermore, when the second transistor 910 is turned on, the major circuit 90 is driven indirectly via the relay 920 to perform a corresponding function when receiving the output power provided by the power supply 4 . The first transistor 900 is turned on when the second transistor 910 is turned off, and the first transistor 900 is turned off when the second transistor 910 is turned on.
Additionally, the electronic device 9 is also capable of being coupled to a conventional power supply. When the electronic device 9 is coupled to the conventional power supply, the voltage of the input port Vin can meets the second requirement, and the first transistor 900 is turned off and the second transistor 910 is turned on, whereby the major circuit 90 can receive the output power.
FIG. 5 shows a flowchart of a power supply control method of the invention. In step S 500 , an electronic device is coupled to and supplied with a power supply. Step S 520 follows, and the power supply transmits a detecting signal to detect whether the electronic device has a memory.
If the result of step S 520 is positive, step S 530 follows, and the power supply converts an input power from an external power source into an output power, and then reads and obtains power information stored in the electronic device in step S 540 . Subsequently step S 550 follows, the output power is adjusted according to the power information and the power supply supplies an adjusted output power to the electronic device.
Adjustment of the output power can be achieved by transforming the power source into output power sources with different potential levels and selecting one of the output power sources to provide the output power to the electronic device. A controller can be employed to read the power information and accordingly sends a control signal to a selector for selection.
If the result of step S 520 is negative, step S 600 follows, and the output power can be manually selected to provide the electronic device with required power.
Finally, while the invention has been described by way of example and in terms of the above, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | Intelligent power supply and control method thereof. A power supply for altering an output power by detecting a power requirement of an electronic device and the electronic device having a memory. The power supply comprises a converter, a control device and a switch. The converter is able to convert an input power into the output power applied to the electronic device. The control device is coupled to the converter reads power information concerning the power requirement from the electronic device and accordingly controlling the converter to adjust the output power. The switch coupled both the converter and the control device receives a control signal of the control device and switches an output port of the power supply to the converter to transfer the output power from the converter to the electronic device. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This Application claims priority from Provisional Patent Application No. 60/269,107 filed Feb. 12, 2001. The entire contents of such Provisional Patent Application are hereby incorporated herein by reference.
SOLID-STATE MICROREFRIGERATOR
The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory.
BACKGROUND OF THE INVENTION
The present invention relates to microrefrigerators and, in particular to a solid-state microrefrigerator based on normal metal-insulator-superconductor (NIS) tunnel junctions. The invention relates especially to a microrefrigerator using a single crystal as both the substrate and superconducting electrode of the NIS junction refrigerator.
NIS tunnel junctions are a promising technology for cooling to temperatures near 0.1 Kelvin (K) from bath temperatures near 0.3 K. These ultralow temperatures are desirable for the operation of thin-film sensors which measure energy deposited by particles and photons with great accuracy. Like any refrigerator, NIS junctions remove energy from one component, the normal metal electrode (a normal metal being any metal not in the superconducting state, e.g. silver, gold, copper) and dissipate a larger power in another component, the superconducting electrode. When a NIS junction is biased at a voltage V slightly below Δ/e, where Δ is the energy gap of the superconductor, current flow through the junction preferentially removes the hottest electrons from its normal electrode. Refrigeration is therefore achieved in a solid-state device that operates without vibration or moving parts.
Cooling by NIS junctions was described by Nahum et al, Applied Physics Letters, 65 (24), 12 December 1994 (See also U.S. Pat. No. 5,634,718.) and development has since been pursued by two groups. The first group, at Harvard University, focused on junctions with dimensions of 10×10 microns or larger. They have produced the largest cooling powers to date, about 40 pW at 0.2 K, but only small reductions in temperature (See Fisher et al., Appl. Phys. Lett., Volume 74, Number 18, page 2705, May 3, 1999). The cause of this limited performance has been identified as heating in the superconducting electrode of these devices (See Ullom et al., Physica B 284-288 (2000) 2036-2038). The second group, at the University of Jyväskylä in Finland, has focused on devices with sub-micron dimensions (one micron or less) fabricated by electron-beam lithography (See U.S. Pat. No. 5,974,806). For devices of this size, heating of the superconducting electrode does not occur and the Jyväskylä work demonstrates that large temperature drops are feasible when this condition is met. Electrons have been cooled from 0.3 K to 0.1 K and photons from 0.3 K to 0.2 K (See Levio et al, AppL. Phys. Lett. 68,1996-1998 (1996) and Levio et al. Jun. 10, 1999). However, owing to the extremely small size of these devices, it is impossible to produce cooling powers much larger than 1 pW per junction at 0.3 K. As a result, these devices are probably only suited to cooling sub-micron sized hot electronic bolometers for millimeter wave measurements. To summarize, the Jyväskylä work demonstrates that if heating in the superconducting electrode can be overcome, substantial reductions in temperature are possible. The work at Harvard has shown that the techniques of Jyväskylä cannot be applied on larger scales for fundamental physical reasons.
If arrays of low temperature detectors are to be cooled, it is essential to provide devices in which the refrigeration junction and the cooling power are both large. It is therefore the purpose of the present invention to overcome the effects that have previously prevented cooling in large NIS junctions.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a microrefrigerator for cooling to temperatures near 0.1 K from bath temperatures near 0.3 K.
It is another object of the present invention to provide such a microrefrigerator providing a large cooling power.
It is another object of the present invention to provide such a microrefrigerator having a large cooling power and also having a large (10s to 100s of microns) NIS junction.
It is a further object of the present invention to provide an NIS refrigerator capable of cooling multiple low temperature detectors or an array of detectors.
It is still another object of the invention to reduce the amount of power that returns from the superconducting electrode to the normal electrode in an NIS refrigerator.
It is still another object of the present invention to keep the density of quasiparticles small in the superconducting electrode in an NIS refrigerator.
Briefly, these and other objects are provided by the present invention in which an ultra-pure superconducting single crystal is both the substrate and the superconducting electrode of the NIS junction of the NIS refrigerator. The refrigerator consists of a large ultra-pure superconducting single crystal forming the superconducting electrode and the device substrate and a thin film normal metal layer on top of the superconducting crystal forming the normal electrode, separated by a thin insulating layer forming a tunnel barrier. The superconducting crystal can be either cut from bulk material or grown as a thick epitaxial film. The large single superconducting crystal allows quasiparticles created in the superconducting crystal due to electrons tunneling from the normal electrode to easily diffuse away from the NIS junction through the crystal to traps of normal metal. This prevents the quasiparticles from returning across the NIS junction. In comparison to conventional thin film NIS refrigerators, the invention provides orders of magnitude larger cooling power by using the large crystal as the superconducting electrode. The invention can cool sensors from 0.3 K to an operating temperature of 0.1 K or 0.05 K and therefore allow operation of a cryogenic photon sensor using a relatively simple pumped helium- 3 refrigerator, or it can be used to extend the operation time below 0.1 K of adiabatic demagnetization refrigerators.
Other objects, advantages and features of the present invention will become apparent from the following description when considered in conjunction with the accompanying drawings wherein like or similar reference characters refer to similar elements in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a schematic cross-sectional drawing of a typical conventional thin film NIS refrigerator;
FIG. 1 b is a partial expanded view of the area identified by dashed line 1 b in FIG. 1 a and illustrating electron tunneling from the normal electrode to the superconducting electrode in the conventional thin film NIS refrigerator;
FIG. 2 is plot of the cooling power of Al, Ta, and Nb junctions versus temperature of the normal and superconducting electrodes;
FIG. 3 is a schematic cross-sectional drawing of a preferred embodiment of the solid-state microrefrigerator of the present invention;
FIG. 4 is a schematic drawing illustrating an embodiment of the present invention for providing an array of microrefrigerators using a single superconducting crystal and/or adapted for cooling a sensor or an array of sensors;
FIG. 5 is a schematic drawing illustrating a “diving board” microrefrigerator suitable for cooling from bath temperatures higher than 0.3 K; and
FIG. 6 is a plot of calculated microrefrigerator temperature versus bath temperature for a 10 micron and a 1 micron thick “diving board” in the microrefrigerator of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIGS. 1 a and 1 b illustrate a conventional NIS refrigerator constructed from thin films. A thin film normal metal electrode (normal electrode) 10 and a thin film superconducting metal (superconducting electrode) electrode 12 are disposed on an insulating substrate 14 , with the normal metal electrode also extending over the superconducting metal electrode. The normal electrode 10 is typically made from a material such as copper (Cu), silver (Ag) or gold (Au); the superconducting electrode 12 is typically made from a material such as aluminum (Al), tantalum (Ta) or niobium (Nb); and the substrate 14 is typically made from silicon (Si) The electrodes 10 and 12 are typically approximately 0.1 micron in thickness. A thin insulating layer 16 is formed between the superconducting electrode 12 and the overlaying normal electrode 10 . Insulating layer 16 may typically formed by oxidation at the surface of the superconducting electrode 12 or a thin insulating layer may be added by various depositon techniques and is typically 10-20 Å° in thickness. Additional wiring to the normal electrode for thermometry and grounding has been omitted for clarity. An NIS junction (tunnel barrier) is present at the interface defined by normal metal electrode 10 , insulating layer 16 and superconducting electrode 12 .
NIS junctions remove energy from the normal electrode 10 and dissipate the power in the-superconducting electrode 12 . The base temperature of any refrigerator is determined by the balance between the cooling power and the thermal load. In NIS tunnel junctions, a fraction of the power dissipated in the superconducting electrode can return to the normal electrode, thus reducing the cooling efficiency of the refrigerator. It is crucial that the NIS refrigerator be designed so that the fraction of power returned is at most a few percent.
Current flow through the NIS junction creates electronic excitations called quasiparticles in the superconducting electrode. The presence of quasiparticles both reduces the cooling power of the junction and leads to the production of phonons when quasiparticles (similar to electron-hole pairs) recombine into superconducting Cooper pairs. The phonons can easily return to the normal electrode, which they then reheat. To minimize these two effects, it is essential that the quasiparticle density in the superconducting electrode be kept small.
However, in a conventional thin film device, the quasiparticle mean free path is at most the film thickness of the superconducting electrode, approximately 0.1 micron, and to exit the junction area, quasiparticles must diffuse a distance proportional to the junction length which can be 10's of microns. As a result, quasiparticles accumulate in the junction region.
In conventional thin film NIS refrigerators, power readily returns from the superconducting electrode 12 to the normal electrode 10 unless the NIS junctions (illustrated by dimension l in FIG. 1 a ) are less than approximately 1 micron. As illustrated in the expanded view of FIG. 1 b , a tunneling electron 18 is unable to exit the superconducting electrode 12 quickly because it scatters many times off of the film (NIS junction) interfaces as indicated by the arrow 20 . The tunneling electron 18 must reach the end 22 of the NIS junction before it can exit the superconducting electrode 12 into a normal metal trap (not shown).
To reduce the amount of power that returns from the superconducting electrode to the normal electrode, the present invention constructs the NIS refrigerator in an entirely new way by making the superconducting electrode a large-volume, ultra-pure single crystal which is both the superconducting electrode of the junction and the substrate. Using the approach of the present invention, device performance will not be degraded by power flow from the superconducting electrode to the normal electrode and the refrigerator size will be limited only by the junction area that can be made without a defect (pinhole) in the tunnel barrier (insulator layer 16 ).
In FIG. 2, the calculated cooling power per square centimeter of junction area as a function of temperature is shown for Al, Ta and Nb superconducting electrodes by solid line 24 , dotted line 26 , and dashed/dotted line 28 , respectively. For a 1 cm 2 aluminum junction at 0.1 K, the cooling power approaches 50 μW which is comparable to a dilution refrigerator. For maximum cooling, it is desirable (1) for the junction to be large so that many electrons can tunnel, and (2) that the insulating barrier be thin (low resistance) so that electrons tunnel easily. For the calculations in FIG. 2, a conservative value (300 Ω μ 2 )for the resistance of the barrier has been assumed. A much higher cooling power is feasible with the present invention if the resistance of the tunnel barrier can be lowered. Resistances as low as 60 Ωμ 2 have been reported.
A schematic drawing of an NIS refrigerator according to the present invention is shown in FIG. 3 . The normal electrode 10 a is disposed on a large-volume, ultra-pure single crystal superconducting electrode 30 . An insulating layer 16 a is formed between the normal electrode 10 a and the superconducting electrode 30 in the usual manner to complete the NIS junction (tunnel barrier) between the two electrodes. A normal metal trap 32 is disposed on the underside of the crystal 30 away from the NIS junction. After tunneling into the superconducting electrode 30 , an electron 18 a (now a quasiparticle), moves without scattering to the normal metal trap 32 . Phonons emitted by recombining quasiparticles are also captured by the trap 32 . A passivation/insulation layer 34 is provided to allow additional wiring to contact the normal electrode 10 a for thermometry and grounding without contacting the superconducting electrode 30 . The bias for the NIS junction is represented by the voltage V applied between the normal metal trap 32 and normal electrode 10 a via contact layer 36 . A thermometer lead 38 is coupled to normal electrode 10 a via contact layer 40 .
The electronic mean free path in ultra-pure crystals can be more than 1000 times larger that in thin films. Not only will the qaisiparticles diffuse away from the NIS junction much more quickly in a bulk crystal, the quasiparticle density will be diluted by the enormously larger volume of the crystal 30 . Since the recombination rate scales as the square of the quasiparticle density, the power load on the normal electrode 10 a due to recombination will be reduced by twice as many orders of magnitude as the quasiparticle density. The superconducting crystal 30 can be either cut from bulk material or grown as a thick epitaxial film. For operation at 0.3 K and above, the superconducting crystal 30 could be, but is not limited to Al, Mo, Sn, Ta, Nb and Pb. Materials suitable for the insulating tunnel barrier between the two electrodes 10 a and 30 include AlO x and SiO x .
In a device like the device in FIG. 3, the electrons in the normal metal can be cooled to less than 0.1 K. Cooling to 0.05 K will require junctions with low leakage resistances because of power dissipation in the leakage resistance of the junction.
Since the polished surface of the single crystal substrate must, with very little modification, form one electrode of the tunnel junction, extreme smoothness is required. Imperfections in the surface reduce the resistance of the tunnel barrier and cause leakage currents which degrade device performance. A second requirement for the single crystal substrate is preservation of the crystalline order of the surface. Damage to the crystal lattice will slow the motion of quaisipaticles away from the junction. There are a range of mechanical, chemical and electrochemical polishing techniques that may provide the required smoothness without damaging the crystal lattice. An RMS roughness of less than 1 nm has been achieved using a combination of mechanical and electromechanical polishing and is expected to be adequate for device fabrication.
A superconductor with a smaller energy gap than Al will have more cooling power below 0.1 K and therefore may be preferable for cooling to 0.05 K. Materials suitable for superconductor 30 in a device for cooling to 0.05 K may include ruthenium (Ru) and titanium (Ti).
Focal plane elements which are separate from the NIS refrigerator can be cooled by extending the normal electrode 10 a of the NIS junction on to a suspended microstructure 42 which is cooled by the NIS refrigerator as shown in FIG. 4 . The fabrication of suspended structures using surface micromachining techniques is well developed technology. The detectors/sensors, represented by sensor 44 , which are mounted on the microstructure 42 are also cooled by the NIS refrigerator. If the thermal conductance between the microstructure 42 and the outside atmosphere is weak, then the sensors on the microstructrure will be cooled by the normal electrode 10 a . Of course, the same large crystal can be used as the superconducting electrode of multiple NIS junctions to allow an array of refrigerators and/or an array sensors to be cooled.
FIG. 5 shows an embodiment of the present invention for cooling from bath temperatures higher than 0.3 K. Using Nb or Ta at 1 K, it is not possible to produce a significant temperature drop when the only thermal isolation is the thermal impedance between the phonons and electrons. A way to overcome this problem is to thin bulk crystals and physically isolate them from the substrate. This can be accomplished using configurations where the crystal is held from one end, two ends, corners or edges. For example, as shown in FIG. 5 a , the superconducting crystal electrode 30 a could be positioned in a “diving board” configuration over etched holes 50 in silicon. The insulating junction layer (not visible), the normal electrode layer 10 b , and the normal trap 32 a are disposed on the superconducting crystal 30 a . The “diving board” is typically 250 microns long and power dissipated in the superconducting electrode 30 a is assumed not to return to the normal electrode because of the thickness of the superconducting electrode.
Calculated base temperatures are shown in FIG. 6 wherein dashed curves 54 and 55 , represent the calculated refrigerator temperature versus bath temperature for a 10 um and a 1 um thick diving board of Ta, respectively. Similiarly, solid curves 56 and 57 represent the calculated refrigerator temperature versus bath temperature for a 10 um and a 1 um thick diving board of Nb, respectively. If 1 μm of clean Ta is sufficient thickness to prevent a buildup of quasiparticles, then it is clear that cooling from 1.2 to 0.3 K is possible. A second Al crystal refrigerator could then be positioned at the end of the “diving board” to cool from 0.3 K to 0.1 K.
The foregoing description of preferred embodiment(s) of the invention is presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. | A normal-insulator-superconductor (NIS) microrefrigerator in which a superconducting single crystal is both the substrate and the superconducting electrode of the NIS junction. The refrigerator consists of a large ultra-pure superconducting single crystal and a normal metal layer on top of the superconducting crystal, separated by a thin insulating layer. The superconducting crystal can be either cut from bulk material or grown as a thick epitaxial film. The large single superconducting crystal allows quasiparticles created in the superconducting crystal to easily diffuse away from the NIS junction through the lattice structure of the crystal to normal metal traps to prevent the quasiparticles from returning across the NIS junction. In comparison to thin film NIS refrigerators, the invention provides orders of magnitude larger cooling power than thin film microrefrigerators. The superconducting crystal can serve as the superconducting electrode for multiple NIS junctions to provide an array of microrefrigerators. The normal electrode can be extended and supported by microsupports to provide support and cooling of sensors or arrays of sensors. | 5 |
FIELD OF THE INVENTION
The present invention relates to the field of tying or fencing, from stakes driven into the ground, supporting one or several wires.
For such applications, the stakes have to fulfill a double function of supporting wires and of maintaining wires under tension for the end stakes. Hence, they have to be adapted to resist stresses, often considerable, in the two perpendicular directions, that is:
parallel to the tying direction for the end stakes due to the tension they support;
perpendicularly to the direction of the wires for the intermediate stakes (in the case of a wind perpendicular to the rows of vine or animals rubbing themselves against the fences).
Moreover, it is desirable that the stakes meet the five following requirements:
They have to allow the unwinding of the wire along the fence prior to fixing it to the desired end, so as to provide a quick placing in position, which is not the case if the wire has, for example, to be threaded into a hole. This requirement is particularly experienced in the case of vineyards, requiring considerable lengths of wire. Indeed and as a function of the spacing between rows, there can be from 4 to 7 kilometers of wire per hectare (10,000 square meters).
Secondly, the stake should not present sharp edges at the points of contact with the wire, or else there would be a premature wear of the wire and, with time, its breaking.
Thirdly, the wire has to be easy to be put in place at the required height when unstretched, but once under tension, it must not come out from its support and disengage itself, which is often the case in shallow or dished regions, the wire being subjected to a force directed upwardly (FIG. 1).
Fourthly, in the case of vines, the lifting wires have to be unstressed and disengaged from their fasteners in order to be repositioned in height as the vegetation grows.
Finally, when metallic stakes are involved, they have to resist the aggression of plant protective products spread on the vines or in the fields. Therefore, treated metals which are relatively costly have to be used. In order to avoid a prohibiting price for the stakes, profiles providing the highest possible strength for a given section have to be used.
None of the fencing systems presently known meet simultaneously all these requirements.
Thus:
the holed angles (FIG. 2) do not allow unwinding the wire, have around their holes protruding edges and do not allow using lifting up wires for vine;
the notched angles (FIG. 3) have sharp edges, which do not prevent the disengagement of the stretched wires when the ground is concave, and have a reduced mechanical strength due to these notches;
the angles with attached bar (FIG. 4) have sharp edges, which do not allow an easy handling of the lifting wires and require an extra device for the fixation of the bars, making the system more costly;
the notched sections, such as those shown in FIGS. 5 and 6, have sharp edges, do not eliminate completely the risk of disengagement of the stretched wire out of the notches where the ground has a ccncave profile and offer a reduced mechanical strength due to the notches;
nor the perforated profiles with fasteners, such as those shown in FIG. 7 are satisfactory. Indeed, the perforations are disposed on the edges perpendicular to the wires and therefore weaken the stake, and their sharp edges cause wear to the wires. Moreover, the fastener does not allow disengagement of the wire for lifting up operations, while fastener b does not avoid the risk for the wire to disengage from the fastener when the ground is undulated.
OBJECTS AND SUMMARY OF THE INVENTION
The fencing or tying system according to the invention provides an assembly of stakes and fasteners meeting simultaneously the five hereabove requirements.
To this effect, the invention relates to a fencing or tying device using wires, stakes and fasteners allowing fixing the wires to the stakes, in which:
the stake is a hollow profile, closed or not, formed at least with two perforations for the fixation of a fastener, said perforations being disposed between two tangential vertical planes containing the stake and parallel to the fencing or tying plane;
the fastener comprises a first portion in the shape of a loop for its fixation into two perforations of the stake, to this loop-shaped portion is connected a horizontal supporting portion for a fencing or tying wire, the length of said supporting portion being such that when the fastener is fixed to the stake, the end of said supporting portion opposite said loop-shaped portion is outside a vertical plane tangent the edge of the stake and parallel to the fencing or tying plane on the side of said fastener, and a portion forming a lock for the fencing or tying wire being connected to this supporting portion, lifted obliquely and upwardly in the direction of the median plane of the stake parallel to the aforementioned tangential plane and the free end of which is between said median and tangential planes.
The stake can be of circular, ellipsoidal section, or of polygonal shape.
When the stake has an opened profile, the perforations or perforation lines are disposed substantially in the portion of the profile which is opposite its opening.
According to a preferred embodiment, a stake comprises two parallel perforation lines disposed in the vicinity of each other, on either side of a median vertical plane of the stake parallel to the fencing or tying plane.
According to another preferred embodiment, the stake is a hollow square sectioned profile, opened at the location of one of its edges, the three other edges of which are rounded and comprises two vertical perforation lines disposed on either side of the edge opposite the profile opening.
Such a profile authorizes a continuous fabrication; the arrangement of the perforations provides an optimnm value of the inertia moment, thereby allowing using lighter profiles for a strength comparable to that of the usual profiles. The use of opened profiles is also the source of savings of material.
The invention relates also to assembly parts for the realization of the end posts from two hereabove stakes and/or for the adaptation of struts on one of said stakes.
The invention relates also to a hook specially provided for cooperating with the stake for the hooking up of the end small chains of the lifting up wires and for the anchoring of the fastening wires and of the streching wires.
Further features and advantages of the invention will become apparent from the following description of a non limiting embodiment.
BRIEF DESCRIPTION OF DRAWINGS
This description refers to the accompanying drawings wherein:
FIG. 1 shows schematically that when the fencing or tying is implanted in a convex ground, the tension of the wire in directions T 1 and T 2 produces a lifting force S tending to disengaging wire 1 from its fasteners on stakes 2.
FIGS. 2 through 7 show various fencing or tying systems presently know.
FIG. 8 is a frontal view of a portion of the stake according to the invention, when looking in the direction of the perforation lines.
FIG. 9 is a horizontal sectional view along line VIII--VIII of FIG. 8.
FIG. 10 is a plan view of a fastener according to the invention.
FIG. 11 is a view similar to that of FIG. 8, the fastener of FIG. 10 being but in position on the stake.
FIG. 12 s a view similar to that of FIG. 8, two fasteners according to FIG. 10 being in place for threading two wires on either side of the stake.
FIG. 13 is a horizontal sectional view along line XII--XII of FIG. 12.
FIG. 14 is a perspective view of a stake according to FIGS. 12 and 13.
FIG. 15 shows an example of an assembly of stakes according to FIG. 8 for forming end posts.
FIG. 16 is a perspective view of a tool specially designed for the installation of stakes according to FIG. 8.
FIG. 17 is a perspective view of a bracing part for forming an end post with two stakes.
FIG. 18 is a profile view of the end of a tying line comprising a post made of two assembled stakes with the bracing part of FIG. 17.
FIG. 19 is a perspective view of an assembly part for a strut.
FIG. 20 is a profile view of a stake provided with a strut assembled with the assistance of the part of FIG. 19.
FIG. 21 is a perspective view of an assembly part for two struts disposed perpendicularly.
FIG. 22 is a plan view of the mounting on a stake of two struts disposed perpendicularly by means of the parts of FIGS. 19 and 21.
FIG. 23 is a perspective view of a special hook for cooperating with the stake.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The stake portion shown in FIGS. 8 and 9 is made of an opened hollow profile 3, of substantially square shape.
The opening 4 is situated at the location of one of the edges of the square.
The three other edges 5, 6 and 7 are rounded.
On either side of edge 6 opposite opening 4 are formed two perforation lines 8, extending vertically on the whole height of stake 3.
The fastener 9, used for cooperating with stake 3, is shown in FIG. 10. It is made advantageously of a spring steel wire folded such as to comprise three portions operatively connected to each other, viz.:
A first fixation portion, loop-shaped, extending from point 10 to point 14 of FIG. 10.
A horizontal support portion of the wire is connected to the loope-shaped portion. It extends from 14 to 15 in FIG. 10.
It is elongated by a lock forming portion extending from 15 to 16, extending obliquely from point 15 in the direction of the upper point 12 of the loop-shaped portion.
The curvature of the loop-shaped portion is such that its free end 10 extends over a certain distance, parallel to the support forming portion and below the latter.
The free end 16 of the lock forming portion is protruding above the upper point 12 of the loop.
In order to put fastener 9 in place on stake 3, as shown in FIG. 11, its end 10 is introduced into a hole 8, at the desired height, said end 10 being thus inside of stake 3. By a rotation movement, said end 10 is forced to move down toward hole 8, immediately below, through which it extends outside the stake. The fastener 9 being preferably made of spring steel wire recovers its initial shape due to its resiliency.
As an alternative, when using for the fastener a non resilient material, the loop is given a shape allowing its introduction by rotation into two successive holes of the profile, then the free end of the loop of the elbow 14 is closed, for example by means of plyers, thereby locking the fastener.
Wire 17, once stretched, is housed inside the connection bend 15, between the support portion and the lock forming portion.
As shown more particularly in FIGS. 11, 12, 13 and 14, the end 15 of the support forming portion of fastener 9 is outside a vertical plane tangent the stake edge 5, 7, said plane being parallel to the tying plane. The lock forming portion is extending obliquely and upwardly in the direction of the median vertical plane 18 of the stake, which is parallel to the aforementioned tangential plane, and its free end 16 is between said tangential and median planes.
In this way, when wire 17 is stretched, it cannot disengage from a fastener 9 under the effect of forces directed upwardly, whereas when unstretched, it can be easily removed from the fastener, for example for lifting up operations.
As shown in FIGS. 12 and 13, the disposition of the two perforation lines on either side of edge 6 of stake 3 authorizes the placing of the wires on either side of the stake.
This disposition of the perforations authorizes on the other hand a combination of several stakes together for forming end posts of high strength.
As a function of the required strength for the end post, such post can be provided by combining two, three or four stakes.
FIG. 15 shows an example of the disposition of four stakes assembled such that their perforations are in register and rigidly connected by bolts passing throughsaid perforations.
FIG. 16 shows a tool 19, specially designed for the installation of stakes 3, according to the invention. This tool comprised a flat body 20, of a thickness allowing it to be introduced through opening 4 of stake 3 and having a width substantially equal to the diameter of said post.
On said flat surface 20 is fixed a head 21.
The flat surface 20 provides a guide for driving in the stake while preventing its buckling, while head 21 which receives the impacts from the sledge causes a better distribution of the forces on the periphery of the stake and prevents its deterioration.
The end posts such as that shown in FIG. 15 are adapted for supporting considerable forces. However, they are difficult to put correctly in place, since their resistance to the penetration in the ground is high.
FIGS. 17 and 18 show an advantageous embodiment of a simplified post made of two stakes, the performance of which is similar to that of a post made of four stakes and the installation of which is much easier.
To this effect, one uses according to the invention at least one and preferably several bracing parts 22 for rigidly connecting two stakes 3 opposed to each other by an opened edge 4.
The bracing part 22 is a profile formed from a bent plate and comprising a web 23, possibly ridged, two portions 24, 25 having a shape corresponding to that of stake 3 but of slightly different size, being connected on either side, so that they can be slided outside or inside a stake.
Portions 24 and 25 are formed with at least two perforations 28, threaded or not, for cooperating with the perforations 8 of a stake 3 for the fixation of the assembly by appropriate means such as screws or bolts.
In the example shown, the shape of portions 24 and 25 of the bracing part 22 is a U-shape, the wings of which are folded substantially at a right angle relative to the bottom.
Two perforations 28, preferably threaded, are disposed on either side of the outer edge 26, 27 of said U-shaped portions 24 and 25, according to two planes spaced vertically from each other by a distance equal to the pitch of perforations 8 of a stake 3.
The U-shaped portions 24 and 25 are disposed symmetrically on either side of web 23 and their connecting face forms with the plane of said web 23 an angle of 135°.
As shown in FIG. 18, the two stakes 3 to be assembled are presented with their opened edges turned toward each other and the U-shaped portions 24 and 25 of the bracing part 22 are slided inside of each stake up to the desired level, the assembly being then fixed by bolts passing through the perforations 8 of stakes 3 and 28 of the U-shaped portions 24 and 25. Preferably, the perforations 28 are threaded holes, allowing omitting the nuts.
The assembly thus formed provides a very resistant beam able to support very important flexural efforts.
The number of bracing parts 22 to be used depends on the height of the post and on the effort to which it is subjected. Generally, a spacing of 50 centimeters is sufficient.
Preferably, the installation of such an end post is carried out according to following operating mode allowing driving in only a single stake at a time.
The number of bracing parts required is fixed on a stake 3, at the desired locations, with the assistance of screws or bolts. Then, said stake 3 is driven in to its final position in the ground with the aid of tool 19. A second stake 3 is then threaded onto portions 24 and 25 left free of bracing parts 22, the assembly already installed acting as a guide for the installing of a second stake, the latter being driven in the same manner as previously and then fixed to the bracing parts 22 with screws or bolts.
For some applications, it can be desirable to provide stake 3 with one or two struts. This is particularly the case when stake 3 is used for a fence or tying in a closed ground in which there is no space beyond the head stake for providing the anchoring or anchorings.
According to the invention, this is made possible by using the special assembly parts 29 and 35 shown in FIGS. 19 and 21.
For mounting a single strut, one uses part 21 shown in FIG. 19. Said part comprises a portion 25', similar to portions 24 and 25 of bracing part 22 and provided for cooperating with stake 3, to which is connected a fixation ear 30, formed with a perforation 32. In the example shown, part 25' is U-shaped, the wings of which are bent a right angle relative to the bottom, ear 30 forming an angle of 135° with the wing to which it is connected. On either side of the edge opposite ear 30 are formed two perforations 31, preferably threaded, in two planes vertically spaced apart by a distance equal to the pitch of the perforations 8 of a stake 3.
As shown in FIG. 20, a part 29 is fixed at the upper end of a stake 3 used for forming a strut, another part 29 is fixed on a second stake 3 and the two are rigidly connected by a bolt 33 passing through the perforations of the two ears 29, after having provided the strut with the required slant.
Preferably, the assembly is made rigid by means of a transverse brace 34 mounted on two extra parts 29 fixed approprately to the stake and to the strut.
For mounting the two struts by the square on stake 3, parts 35 are used, such as those shown in FIG. 21 and parts 29.
Part 35 includes a portion 36 having a shape corresponding to that of stake 3, but of a size slightly different. To this portion are connected two fixation ears 37 diverging outwardly, forming between themselves an angle having the same value as that of the closings, and generally a square angle.
The ears 37 include, as ear 30 of part 29, a perforation 32. Portion 36 is formed with perforations 31 for cooperating with the perforations 8 of a stake.
In the example shown in FIG. 21, the portion 36 of part 35 is an opened square profile the two opened edges of which are prolongated by ears 36 diverging outwardly and forming therebetween a straight angle.
The perforations 31, preferably threaded, are disposed on either side of the edge opposite the opening of profile 36 according to two planes vertically spaced apart by a distance equal to the pitch of the perforations 18 of a stake 3.
With this part 35, it is possible, in a manner similar to that hereabove described for part 29, to mount on a stake 3 two struts disposed in perpendicular planes, as shown in a plan view in FIG. 22.
Each of the struts is made of a stake or a portion of stake 3 at the head of which is bolted an assembly part 29. Transverse braces can also be mounted by means of an extra part 35 and two other parts 29.
As previously decribed, stake 3 and its fastener 9 have been designed such as to avoid any sharp edge at the locations where the wires bear, so as to reduce the wear of the latter. For the same purpose, the invention provides for the fixation of the various wires and anchoring elements on the end stakes a hook 38 adapted to the perforations 8 of stake 3.
Said hook 38, shown in FIG. 23, is made of a preferably metallic and S-shaped wire, the loops of which have a large opening. Preferably, the two loops of the hook are disposed into two different planes.
Due to its its S shape with a large opening, hook 38 allows a very easy positioning in height of the various wires being anchored to an end stake, viz. the stretching wires 39, the anchoring wires 40 and the lifting up wires 41 (FIG. 18).
Hook 38 is simply passed through two adjacent perforations 8 of stake 3, placed in the same horizontal plane, while the wires are anchored on its loop left free.
Hook 38 allows also using, together with stake 3 according to the invention, the current lifting devices, such as the small chains 42 (FIG. 18) | A wire fence has a hollow elongated stake for supporting a horizontal wire. The stake has vertical rows of perforations for receiving wire fasteners. The perforations are positioned between two vertical planes tangent to vertical extending edges of the stake, the planes being parallel to the wire. The fastener has a loop for insertion into the perforation, a wire support section extending outwardly through the vertical planes, and a free end at the end of the wire support section, which is bent back toward the loop portion so that the wire is held in place. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority of a prior filed Provisional Patent Application having Ser. No. 60/767,384 and official filing date of Mar. 23, 2006 and which discloses the same subject matter.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTTED ON A COMPACT DISC
Not applicable.
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Present Disclosure
This disclosure relates generally to a system for mounting a pouch to a garment at any selected location and more particularly to a fastener for enabling such a system.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
Splane, Jr., U.S. 2003/0014844, discloses a removable storage device to enable storage of personal articles on the person of a user. The device includes a pair of snap fit elements. One element includes a recess for receiving a portion of the other element as a snap fit therein so as to permit a portion of an article of clothing worn by the user to be captured between the elements when the elements are snap fit together to thereby removably affix the elements to the article of clothing. One of the snap fit elements includes a support member or arrangement (e.g., a D-ring or a pocket) for supporting a personal article.
Butler, U.S. Pat. No. 1,682,771, discloses a separable button, a base, a shank formed on one face of the base and formed with front threads for its entire length, and over which a piece of fabric is adapted to be disposed, a split resilient ring encircling the fabric covered shank at the juncture of the shank with the base, a head provided with a threaded socket in the inner side thereof, and an internally threaded collar formed on the inner side of the head and extending outwardly therefrom around the socket, the fabric covered threaded shank being removable secured in the socket and collar.
Sperling, U.S. Pat. No. 3,865,290, discloses a tennis ball holder is comprised of a lightweight, vacuum-formed, concave plastic shell having a plurality of fingers which grip the ball to retain the ball within the shell. The rear wall of the shell is generally flat and contains a keyhole. In use, the holder is placed with its rear wall against the outside of the player's clothing at a convenient place. Then a flat plate is positioned underneath the clothing opposite the holder. The plate has a key arranged to project into the keyhole along with the fabric and lock there so as to securely anchor the holder and the ball contained therein to the player's clothing, freeing his hands for play.
Gillis, U.S. Pat. No. 4,308,647, discloses a clip is provided which is adapted for fastening onto a flexible web such as a sheet of fabric. The clip is particularly adapted for fastening the fabric of a tent to supporting poles or stakes or for fastening webs together.
Devenny, U.S. Pat. No. 4,559,675, discloses an invention that is a support for fastening a decorative object such as a flower or corsage to an article of clothing comprising a pair of elements having cooperative shapes such that one clamps into the other, from one side thereof. A decorative object is secured to one of the elements. Accordingly, one of the pair of elements can be clamped into the other from opposite sides of the article of clothing, clamping and catching the article of clothing therebetween and securing it thereto.
Hooper, U.S. Pat. No. 4,985,968, discloses a decorative body member that includes a safe and harmless separable, interlocking fastening device for engaging a portion of a garment therebetween. In one embodiment, an elongated ribbon is attached at one end to the body member and at the other to a pacifier, teething ring, or toy, to avoid loss. The fastener includes a circular pattern of fingers or prongs (female element) extending from the rear surface of the body member. The male element is a disk which is received within the fingers with the fabric therebetween. The disk is sufficiently large to prevent swallowing, and preferably includes an aperture through the center thereof to provide for passage of air if the disk should become lodged in the mouth or inadvertently swallowed.
Maxwell-Trumble et al., U.S. Pat. No. 5,655,271, discloses a clothing accessory that includes a molded plastic plate and a molded plastic ring. The periphery of the plate is provided with a first engagement surface and the interior of the ring is provided with a second engagement surface. The relative dimensions of the plate and the ring are chosen such that the fabric of an article of clothing can be engaged between the first and second engagement surfaces. More specifically, when the ring is placed on one side of a fabric and the plate is placed on the other side of a fabric, the plate and ring may be pressed together so that the plate is frictionally engaged inside the ring by the fabric of the clothing. According to a presently preferred embodiment, the engagement surfaces are V-shaped. I.e. one of the surfaces is a concave V-shaped groove and the other is a convex V-shaped edge. Other preferred aspects of the invention include providing a peripheral lip on the plate which extends substantially orthogonal to one side surface of the plate to define an image receiving area. According to the invention, a photograph, hologram or other decorative indicia is attached to the plate by providing the indicia on a material which is attached to the plate with an adhesive. Preferably, the material is a self-adhesive, peel and stick material. A kit according to the invention, includes a plate, a ring, and a plurality of self-adhesive labels, each bearing different decorative indicia.
Denison, U.S. Pat. No. 5,926,920, discloses a snap-in adapter system that includes an interior piece having a circular interior face and a short cylindrical side wall forming a cylindrical recess, the recess having an interior diameter. The system also includes an exterior piece. The exterior piece has a circular exterior face with a diameter essentially equal to that of the diameter of the recess of the interior piece. The exterior piece also has a cylindrical projection. Also provided is an attachment means.
Fong, U.S. Pat. No. 5,940,942, discloses a fabric holder to secure a plurality of fabrics together. The apparatus comprises two pieces, a male bottom piece and a female top piece which interlock to secure the fabric.
Chen, U.S. Pat. No. 6,223,399, discloses an adornment clamping device which is able to secure the adornment to the base of an item. The device has an elongate bar securely connected with the base by means of a neck, an adornment having a through hole defined to allow the elongate bar to be inserted there through and having a press fit therewith and a slit defined to communicate with the through hole, such that when the elongate bar extends through the through hole of the adornment, the adornment is able to be secured by the press fit between the protrusion formed on the neck and the slit.
The related art described above discloses numerous two-part fastener for wedging a cloth garment therebetween for mounting an item on the garment. However, the prior art fails to disclose an integral fastener with two flanges that is mountable in an aperture of the item to be mounted and which secures the item on the garment. As well, the prior art fails to teach a locking element that is engaged with the fastener after it is mounted. Finally, the prior art fails to teach the use of an elongated flange that may be preferably biased in a position where it is impossible to disengage from the item being attached to the garment. For these reasons, the present disclosure distinguishes over the prior art providing heretofore unknown advantages as further described in the following summary and detailed description and illustrated in the attached drawing sheets.
BRIEF SUMMARY OF THE INVENTION
This disclosure teaches certain benefits in construction and use which give rise to the objectives described below.
A fastener system mounts a pouch onto a shirt or other clothing article, wherein the pouch provides a receptacle aperture into which a fastener is placed with its flanges positioned on opposing sides of the aperture. The cloth to which the fastener is mounted is gripped between the fastener and the aperture and is locked into place by a U-shaped clip. The flanges are made oblong in shape so that the narrow orientation of the flanges easily pass through the aperture, but the longer orientation cannot. Flats may be applied to both aperture and the fastener so as to assure an orientation in use wherein the fastener cannot disengage from the pouch.
A primary objective inherent in the above described apparatus and method of use is to provide advantages not taught by the prior art.
Another objective is to provide a means for mounting a pack or pouch onto a shirt or other article of clothing.
A further objective is to provide such a mounting means that may be placed at random.
A still further objective is to provide such a mounting means with a security locking device to assure that the mount cannot loose its hold.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the presently described apparatus and method of its use.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
Illustrated in the accompanying drawing(s) is at least one of the best mode embodiments of the present invention In such drawing(s):
FIG. 1 is a perspective view of the presently described apparatus in use on a person;
FIG. 2 is a partial close-up view thereof;
FIG. 3 is an exploded view of the several items thereof; and
FIG. 4 is a partial cross sectional view thereof taken along line 4 - 4 in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
The above described drawing figures illustrate the described apparatus and its method of use in at least one of its preferred, best mode embodiment, which is further defined in detail in the following description. Those having ordinary skill in the art may be able to make alterations and modifications to what is described herein without departing from its spirit and scope. Therefore, it must be understood that what is illustrated is set forth only for the purposes of example and that it should not be taken as a limitation in the scope of the present apparatus and method of use.
Described now in detail is a fastener system for randomly mounting a pouch 10 on a fabric article 20 such as a garment, where the fabric article 20 need have no means for receiving the pouch such as a button hole, a clip, a clasp or a pin. The pouch 10 has a sheet portion 12 extensive to and preferably integral with a portion for receiving at least one article so as to fulfill the purpose of the present apparatus; to carry articles on ones person at a selected body location without the need for additional attachment hardware other than a fastener 30 designed for the purpose.
The sheet portion 12 provides a receptacle aperture 14 as best shown in FIG. 3 preferably an elongated slit as illustrated. The fastener 30 is constructed of plastic preferably, and has a pair of flanges 32 and 34 which are held in spaced apart positions by an integral connector 36 . The connector 36 has a connector diameter “D.” As shown in FIG. 4 , the connector 36 is inserted into the receptacle aperture 14 from one side 22 of the fabric article 20 thereby positioning the pair of spaced apart flanges 32 , 34 on opposing sides of the sheet portion 12 of the pouch 10 and engaging the fabric article 20 between the sheet portion 12 and the fastener 30 . The flanges 32 , 34 are extensive relative to the receptacle aperture 14 for capturing the fastener 30 and the fabric article 20 within the sheet portion 12 . Clearly, with the sheet portion 12 of fabric article 20 engaged as shown in FIG. 4 , the pouch 10 is not able to move relative to the fabric article 20 .
To insure a more positive lock between pouch 10 and fabric article 20 , a U-shaped clip 40 is engaged between the pair of flanges 32 , 34 as shown in FIG. 4 . Preferably, the U-shaped clip 40 is of a resilient material formed with opposing legs 42 separated by a first distance 45 ′, the legs 42 mutually joined at one end 44 of each of the legs 42 . Preferably, the opposing legs 42 provide mutually facing detent surfaces 46 , the detent surfaces separated by a second distance 45 ″, the second distance exceeding the first distance 45 ′ and is approximately equal to the connector diameter “D”.
Preferably, the flanges 32 , 34 are oblong in shape having a smaller girth G 1 in a first orientation and a larger girth G 2 in a second orientation as shown in FIG. 3 , the receptacle aperture 14 is preferably elongate in shape and sized for receiving the smaller girth G 1 , but not the larger girth G 2 . Preferably, the aperture 14 has a flat 16 at one end thereof and the connector 36 has a corresponding flat 38 , although in stead of a flat, the connector 36 may be formed with an oval shape. After insertion of the flange 34 into the aperture 14 and then rotating the fastener 30 so that the flats 16 and 38 abut, or a longer side of the overall shape abuts the flat 16 , the larger girth G 2 is aligned with the elongate shape of the aperture 14 so that the flanges 32 and 34 are not able to disengage with the elongate slot 14 and the weight of the pouch (pressing downward by its weight) prevents the from rotating away from the abutting relationship until manually and purposefully rotated after relieving the weight biasing.
The fabric article 20 clearly may be almost any article of clothing or similar articles such as shirts, a jackets and a pairs of pants, but can also be any relatively flexible fabric such as a curtain, a blanket, and so on, while the pouch 10 may be any item that one wishes to carry on their person or otherwise without the use of fasteners such as pins and clips. Typical articles include money holders, a firearm holsters, and utility bags. The item however, must have a sheet portion 12 that is able to be married with the fastener 30 using the aperture 14 .
The method of the present invention, i.e., the method of use includes the steps of abutting the first flange 32 of a fastener 30 against a portion of a fabric article 20 and then pressing the first flange 32 and the portion of the fabric article 20 through the aperture 14 in the sheet portion 12 of the pouch 10 so that the first flange 32 is positioned on one side of the sheet portion 12 , while the second flange 34 is positioned on the opposing side as shown in FIG. 4 and so that a portion of the fabric article 20 extends through the aperture 14 . Next, the U-shaped clip 40 is slid between the first and second flanges 32 and 34 thereby positioning detent surfaces 46 against the connector 36 , so as to lock the fastener 30 within the aperture 14 , and in this way the pouch 10 is mounted onto the fabric article 20 as shown in FIGS. 1 and 2 . The flanges 32 , 34 when formed as oblong in shape as described above, and when the flat 16 at one end of the aperture 16 and at the flat 38 at one position on the connector 36 abut, the larger girth G 2 is aligned with the length of the aperture 14 thereby preventing the fastener 30 from disengaging with the sheet portion 12 of pouch 10 .
The enablements described in detail above are considered novel over the prior art of record and are considered critical to the operation of at least one aspect of the apparatus and its method of use and to the achievement of the above described objectives. The words used in this specification to describe the instant embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification: structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use must be understood as being generic to all possible meanings supported by the specification and by the word or words describing the element.
The definitions of the words or drawing elements described herein are meant to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements described and its various embodiments or that a single element may be substituted for two or more elements in a claim.
Changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalents within the scope intended and its various embodiments. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. This disclosure is thus meant to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted, and also what incorporates the essential ideas.
The scope of this description is to be interpreted only in conjunction with the appended claims and it is made clear, here, that each named inventor believes that the claimed subject matter is what is intended to be patented. | A fastener system mounts a pouch onto a shirt or other clothing article, wherein the pouch provides a receptacle aperture into which a fastener is placed with its flanges positioned on opposing sides of the aperture. The cloth to which the fastener is mounted is gripped between the fastener and the aperture and is locked into place by a U-shaped clip. The flanges are made oblong in shape so that the narrow orientation of the flanges easily pass through the aperture, but the longer orientation cannot. Flats may be applied to both aperture and the fastener so as to assure an orientation in use wherein the fastener cannot disengage from the pouch. | 8 |
BACKGROUND
Flapper valves and other types of downhole valves can be damaged if a tool string is allowed to pass through them when they are in the closed condition. For example, the tool string run through the valve can damage the valve's flapper when closed. Also, the tool string even if capable of passing through the closed flapper may not be allowed to pass back up through the flapper so that the tool sting becomes trapped by the valve.
From the surface, operators do not always know if the flapper in these type of valves is open or not. Typically, operators must run a wireline drift tool through the valve to determine if the flapper is open or closed. If the flapper is open, then the drift tool is able to pass through. If the flapper is closed, the drift tool will stick through the flapper which then activates an artificial hold open sleeve to allow for the drift tool to be retrieved. Another way operators can determine whether a flapper is open or closed involves running a camera downhole and feeding back images to the surface.
Sometimes, a downhole valve may have dogs that engage a specifically designed stringer used to open and close the valve. For example, Weatherford's completion isolation valve (CIV) is a ball type valve actuated by a stinger. Dogs in the CIV engage the stinger and allow the stinger to move internal components to open and close the valve's ball seal. In this instance, these dogs move with the internal components of the valve that operate the ball seal. Therefore, these dogs are directly used to operate the valve by engaging the stinger and not to passively prevent a generic type of tool from being passed through the valve when closed.
What is needed is a way to reliably and easily prevent potential damage to a downhole valve by a generic tool string and to prevent entrapment of the tool string in the valve by passively preventing mechanical passage of the tool string in the valve when closed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a passable no-go device for a downhole flow control tool in a no-go condition.
FIG. 1B illustrates the passable no-go device in the no-go condition preventing a tool string from passing into the downhole flow control tool.
FIG. 2A illustrates the passable no-go device in a passable condition.
FIG. 2B illustrates the passable no-go device in the passable condition allowing a tool string to pass into the downhole flow control tool.
FIGS. 3A-3B show an alternative arrangement between the tool's flow tube and the passable no-go device.
FIGS. 3C-3D show another alternative arrangement between the tool's flow tube and the passable no-go device.
FIG. 4A illustrates the passable no-go device in the no-go condition used on a hydraulically actuated flapper valve when closed.
FIG. 4B illustrates the passable no-go device in the passable condition used on the hydraulically actuated flapper valve when opened.
DETAILED DESCRIPTION
A passable no-go device 50 illustrated in FIG. 1A is used with a downhole flow control tool having a housing 10 and an actuator 20 . The flow control tool can be a downhole valve, and the actuator 20 can a flow tube hydraulically actuated between first and second positions to control fluid flow through the housing 10 by actuating a flapper (not shown) in the tool. The device 50 includes an activation member 60 , a support 70 , and dogs 80 . The support 70 fits into the housing's flow passage 12 , and an end piece 30 fits on the end of the housing 10 and holds the support 70 therein. The support 70 has windows 72 that hold the dogs 80 therein. The dogs 80 are movable into and out of the windows 72 relative to the housing's flow passage 12 , and springs 74 connect the dogs 80 to the support 70 and bias the dogs 80 to a retracted position in the windows 72 .
As shown in FIG. 1A , the activation member 60 attaches to a distal end of the actuator 20 (e.g., flow tube) by threads 62 , although other forms of affixing the member 60 to the flow tube 20 can be used. The member 60 has a distal lip 64 that is passable in a space behind the dogs 80 to force the dogs 80 to a no-go condition through the windows 72 . In this no-go condition as shown, the dogs 80 extend partially into the housing's flow passage 12 . To prevent the dogs 80 from passing completely through the windows 72 , the dogs 80 can have ledges or shoulders (not shown) along their back edges that engage sides of the windows 72 . Preferably, the lip 64 has a smaller inner diameter to fit in the space behind the support 70 . Also, the support 70 preferably has the same diameter bore as the tool's flow passage 12 so that as little flow restriction occurs as possible.
As shown in FIG. 1B , the extended dogs 80 inhibit or restrict a tool string T attempting to pass through the device 50 in the housing's flow passage 12 while the lip 64 on the flow tube 20 forces the dogs 80 into their no-go condition. As discussed below, this no-go condition may occur when the flow tube 20 is moved into a first (uppermost) position in the tool's housing 10 , for example, when a hydraulically activated flapper valve is closed.
As shown in FIG. 2A , the passable no-go device 50 has a passable condition when the activation member 60 on the flow tube 20 is moved away from the support 70 . In this condition, the lip 64 is removed from the space around the support 70 , and the springs 74 bias the dogs 80 out of the support's windows 72 . Therefore, the dogs 80 are allowed to move into the free space around the support 70 . In this passable condition, a tool string T is mechanically uninhibited or unrestricted by the dogs 80 as the tool string T passes through the tool's housing 10 as shown in FIG. 2B . As discussed below, this passable condition may occur when the flow tube 20 is moved into a second (lower) position in the tool's housing 10 , for example, when a hydraulically activated flapper valve is opened.
In addition to preventing a tool string T from passing through a closed flow control tool, the passable no-go device 50 may advantageously prevent (full) closure of the downhole flow control tool when the tool string T is positioned through the opened tool. When the tool is open as shown in FIG. 2B with the tool string T passing through, the retracted dogs 80 positioned in the space around the support 70 can stop the upward movement of the flow tube 20 by engaging the lip 64 . Even though the lip 64 is made to fit behind and push the dogs 80 and may have a beveled edge, the dogs 80 may be prevented from extending through the windows 72 by engaging the profile of the tool string T passing through the flow passage 12 . In this way, the lip 64 and flow tube 20 are not allowed to reach their uppermost position because the dogs 80 cannot extend. This can prevent full closure of the flow control tool and can prevent some forms of damage to the tool.
Although the activation member 60 is shown as a separate component from the flow tube 20 in FIGS. 1A through 2B , the features of the lip 64 can be integrally formed with the flow tube 20 . As shown in FIGS. 3A-3B , for example, the lip 64 can be integrally formed on the end of the flow tube 20 and can operate in the same way discussed above to move behind and away from the space around the support to move the dogs 80 . In another alternative shown in FIGS. 3C-3D , the lip 64 can be part of an independent activation member 60 unattached to the flow tube 20 . In this way, abutting engagement of the flow tube 20 with the activation member 60 can move the lip 64 in the space behind the support 70 . In this arrangement, the member 60 may have ridges 66 or the like that are held within slots 14 defined in the housing's flow passage 12 to guide the member's movement. In addition, the member 60 may be biased away from the support 70 by one or more springs 68 (shown here as extension springs) when the flow tube 20 is moved away from the member 60 .
The passable no-go device 50 can be used with any downhole flow control tool that controls fluid flow therethrough but must also allow tool strings to pass through the tool when opened. Some suitable downhole flow control tools for use with the passable no-go device 50 include safety valves, downhole control valves, downhole deployment valves, fluid loss valves, and the like.
As shown in FIGS. 4A-4B , for example, the passable no-go device 50 is shown used with a hydraulically actuated flapper valve 100 . In this example, the valve 100 has a housing 110 with a flow passage 111 . In the valve 100 , a flow tube 120 in the flow passage 111 acts as an actuator and is hydraulically actuated between first and second conditions. A flapper 118 acts as a closure member for the flow passage 110 and is mechanically operated between opened and closed conditions by the flow tube 120 .
In operation, the absence of hydraulic pressure at a hydraulic port 112 allows the flapper 118 to pivot closed and restrict fluid flow through the valve 100 as shown in FIG. 4A . When hydraulic pressure is applied as shown in FIG. 4B , the hydraulic control fluid communicated through the port 112 actuates a piston 114 connected to the flow tube 120 by a coupling 116 . The hydraulically actuated piston 114 thereby moves the flow tube 120 downward in the housing 110 to open the flapper 118 and permit fluid flow through the valve 100 . A spring (not shown) may be provided in the space around the flow tube 120 to bias the flow tube 120 to its uppermost position so that the flapper 118 is biased closed.
When the flapper 118 is closed as shown in FIG. 4A , it is preferred that a tool string is not allowed to pass through the valve 100 because the tool string could damage the closed flapper 118 . Even if a tool string were allowed to pass the closed flapper 118 , operators may not be able to back out the tool string because the flapper 118 may catch on portions of the tool string preventing its retrieval from the valve. To overcome these problems, the passable no-go device 50 installed as part of the flapper valve 100 passively reacts to the opened or closed condition of the valve 100 to either permit or restrict mechanical passage of a tool string through the valve 100 .
To do this, the passable no-go device 50 prevents the tool string from reaching the flapper 118 when closed by tying its operation to the independent operation of the flapper valve 100 , which is hydraulically actuated by separate means. In other words, the passable no-go device 50 acts as a restricting member mechanically operated by the flow tube 120 and responds to the closing of the flapper 118 by the upward moving flow tube 120 so that the dogs 80 extend and prevent mechanical passage of the tool string through the valve 100 . As shown in FIG. 4A , the flapper 118 is closed because the flow tube 120 is moved to its uppermost position in the housing 100 . The activation member 60 moved by the flow tube 120 fits behind the support 70 and pushes the dogs 80 into the valve's flow passage 111 . In this restrictive no-go condition, the device 50 at least partially restricts mechanical passage through the flow passage 111 because the dogs 80 can mechanically restrict a tool string from getting to the flapper 118 while closed.
On the other hand, the passable no-go device 50 responds to the opening of the flapper 118 by the downward movement of the flow tube 120 when the valve 100 is opened so that the dogs 80 retract and allow mechanical passage of the tool string through the valve 100 . As shown in FIG. 4B , the flapper 118 is opened because the flow tube 120 has been hydraulically moved to its lowermost position in the housing 100 . The activation member 60 on the upper end of the flow tube 120 is moved away from the support 70 and allows the dogs 80 to retract from the valve's passage 111 . In this unrestrictive passable condition, the dogs 80 will not restrict a tool string from passing through the valve 100 , removes the mechanical restriction through the valve 100 .
As will be appreciated, the passable no-go device 50 eliminates the need for an initial discovery run with a camera or a drift tool to be performed to determine if the flapper 118 is first open before running a tool string through the flapper valve 100 . Instead, the tool string can be run down hole. If the valve 100 is inadvertently left closed or is inoperable for some reason, then the passable no-go device 50 can prevent further passage of the tool string to the valve 100 . This can speed up running in and out of the wellbore and can reliably reduce the potential of damage to the flapper 118 or a stuck tool string.
The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof. | A downhole valve has a flow tube hydraulically actuated to open and close a flapper. The flow tube moved to a first position closes the flapper to restrict flow through the valve. The flow tube moved to a second position opens the flapper. A passable no-go device disposed in the valve permits or restricts mechanical passage through the valve in response to the position of the flow tube. The apparatus has a support and one or more dogs supported in windows of the support and biased by springs. The flow tube in the first position pushes the dogs to an extended position that restricts mechanical passage through valve so that a tool cannot be passed through the valve while the flapper is closed. When the flow tube is in the second position, however, the dogs retract so the tool can be passed through the valve while the flapper is open. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application incorporates by reference and claims priority to U.S. Provisional Application 61/786,325 filed on Mar. 15, 2013.
BACKGROUND OF THE INVENTION
[0002] The present subject matter relates generally to decking systems. More specifically, the present invention relates to a plastic or composite exterior decking system that includes a simple snap locking fastener system for installation.
[0003] Previous decking solutions suffer from several drawbacks. For example, conventional decking solutions require complicated and cumbersome installation of current deck products. For example, the decking solutions often included a user to manually space and align each deck board for the proper installation of the deck boards. Such solutions result in many failed attempts at evenly spaced deck boards and hours of frustration on the user's behalf.
[0004] Further, previous decking solutions lack weather protection for underlying deck joists. As a result, existing systems often have exposed fasteners that detract from the appearance of the deck and allow the elements to directly effect the fasteners causing them to rust or discolor.
[0005] In addition, previous decking solutions are typically made in designs and of materials that degrade in response to expansion and contraction caused by seasonal fluctuations in temperature.
[0006] Accordingly, there is a need for a decking system that is simple to install, spaces itself automatically, provides weather protection to the deck joists and fasteners, and resists degradation due to expansion and contraction, as described herein.
BRIEF SUMMARY OF THE INVENTION
[0007] The present disclosure provides a solution to the above mentioned problems. Specifically, the system may include a receiver and deck plank, wherein the plank removeably connects to receiver for installation. For example, the receiver may provide a snap lock function that secures and automatically spaces the deck planks on the receiver, which is fastened to a deck joist. The receiver may further act as a flashing for the deck joists to protect the deck joists from the elements. In addition, the planks are adapted to snap onto the snap lock receiver and act as a cover to protect the underlying fasteners. The receiver may be injection molded from any of a number of different materials including, but not limited to, aluminum, polyvinyl chloride (PVC), and polypropylene, to name a few. The planks may be extruded from any number of different materials including, but not limited to, aluminum, polyvinyl chloride (PVC), and polypropylene, to name a few.
[0008] The receiver is installed directly on a deck joists and acts as a receiver for the plank while also acting as a flashing for the deck joist. The receiver includes a plurality of retainers that provide automatic spacing for the deck planks. For example, once the receiver is in place the deck planks are simply pressed or snapped on to the receiver. The decking planks are adapted to shed water and resist the accumulation of water, ice or snow by incorporating a design that includes a convex plank top surface, a point for a continuous drop, and a void in the plank edge to allow for proper water drainage. Once installed if a single deck plank needs to be removed for whatever reason the planks can simply be slid off the end and reinstalled.
[0009] In an embodiment, the system includes a receiver and plank, wherein the receiver includes a receiver body including a receiver top surface and an receiver bottom surface. The receiver further includes a retainer extending from the receiver top surface, wherein the retainer has a retainer first end and a retainer second end, wherein the retainer first end extends from the retainer interior surface. The retainer second end may be conical shaped. In yet another example, the retainer is integrally formed with the receiver.
[0010] The plank includes a plank body including a plank top surface, plank bottom surface, and two plank edges. The plank may be a deck board. In an example, the plank top surface is convex. The plank further includes a set of arms extending perpendicular from the plank bottom surface, wherein each arm includes an arm first end and an arm second end, wherein the arm first end extends from the plank bottom surface, wherein the arm second end includes a tab extending parallel to the plank body. The retainer first end is configured to receive the tabs of the set of arms. When the tabs of the arms are engaged with the retainer of the receiver, the arms maintain a space between the receiver top surface and the plank bottom surface. The tab may include a tab end that is tapered.
[0011] The receiver may include a plurality of retainers periodically spaced along a length of the receiver. The retainer first end includes a retainer groove on each side of the retainer for receiving the tabs of a set of arms.
[0012] In an example, each plank edge includes an arm extending from the interior surface of the plank body, wherein the arm second end includes a tab extending parallel to the plank of the body. In addition, the arm second end may include a point to enable a continuous drip from the plank.
[0013] The system may further include at least one fastener configured to connect the receiver to a deck joist, wherein at least a portion of the fastener resides in a portion of the space between the receiver top surface and the plank bottom surface.
[0014] In another embodiment, the system includes a receiver, a plank, and a deck board. The receiver includes a receiver body including a receiver top surface and a receiver bottom surface. The receiver further includes a retainer extending from the receiver top surface, wherein the retainer has a retainer first end and a retainer second end, wherein the retainer first end extends from the receiver top surface. In an example, the retainer is integrally formed with the receiver.
[0015] The plank includes a plank top surface, plank bottom surface, and two plank edges. The plank further includes a set of arms extending perpendicular from the plank bottom surface, wherein each arm includes an arm first end and an arm second end. The arm first end extends from the plank bottom surface, wherein the arm second end includes a tab extending parallel to the plank body.
[0016] The deck board includes a deck board body including a board bottom surface, a board top surface, and board ends, wherein the deck board body is configured to mate with the plank body. In an example, when the deck board body mates with the plank body, the deck board body conceals the plank from view. The deck board ends may include a board groove for receiving the plank edges. In another example, the deck board ends include a point to enable a continuous drip from the deck boards.
[0017] The retainer first end is configured to receive the tabs of the set of arms. When the tabs of the arms are engaged with the retainer of the receiver, the arms maintain a space between the receiver top surface and the plank bottom surface.
[0018] The system may include at least one fastener configured to connect the receiver to a deck joist, wherein at least a portion of the fastener resides in a portion of the space between the receiver top surface and the plank bottom surface.
[0019] An objective of the invention is to provide a solution to the complicated and cumbersome installation of current deck products, including providing a solution to spacing of the deck planks.
[0020] Another objective is to provide weather protection to the deck joists and to resist degradation and other issues due to seasonal expansion and contraction, as well as a means of concealing the installation fasteners.
[0021] An advantage of the present system is that it simplifies a decking installation process by providing a system that inherently provides equal spacing for the deck planks.
[0022] A further advantage of the present system is that it conceals the installation fasteners, making it more aesthetically pleasing while providing protection to the installation fasteners from the environmental elements.
[0023] Another advantage of the invention is that it provides improved water control and does not allow moisture to accumulate anywhere in or on the system.
[0024] Yet another advantage is that the positioning of the installation screws is directly below the decking board, thus they are concealed and out of sight and are also out of direct exposure to weather.
[0025] A further advantage of the invention is that the use of materials and designs that resist degradation due to seasonal expansion and contraction.
[0026] Additional objects, advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
[0028] FIG. 1 is a front cross-sectional view of an embodiment of the system in combination with a deck joist.
[0029] FIG. 2 is a side cross-sectional view of an embodiment of the system disclosed herein including a plank installed onto the receiver.
[0030] FIG. 3 is a side cross-sectional view of an example of a plank disclosed herein.
[0031] FIG. 4 is a side cross-sectional view of an embodiment of the system disclosed herein including a deck board installed on a plank, which is installed on a receiver.
[0032] FIG. 5 is a side cross-sectional view of an embodiment of a plank disclosed herein.
[0033] FIG. 6 is a side cross-sectional view of an embodiment of a deck board disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0034] As shown in FIGS. 1-2 , the present disclosure provides a decking system 10 that includes a receiver 12 and plank 14 that may removeably attach to each other. For example, the plank 14 may snap, slide, or otherwise temporarily lock into the receiver 12 .
[0035] FIG. 2 depicts the receiver 12 including a generally linear receiver body 16 including a receiver top surface 18 and a receiver bottom surface 20 . The receiver 12 further includes a retainer 22 extending from the receiver top surface 18 . The retainer 22 may be integrally formed with the receiver 12 , or a separate entity that is otherwise attached to the receiver 12 . As shown in FIG. 2 , the receiver 12 may include a plurality of retainers 22 . The retainers 22 may be spaced periodically such that the position of the retainers 22 on the receiver 12 enables a user to attach planks 14 , such as deck boards, that will automatically be aligned. In other words, the spacing of the retainers 22 prevents users from having to measure and align the deck boards themselves, a frustrating and cumbersome process.
[0036] The retainer 22 has a retainer first end 24 and a retainer second end 26 , wherein the retainer first end 24 extends from the receiver top surface 18 . The retainer 22 may have any suitable shape. In an example, the retainer second end 26 may be conical shaped. Although, it is contemplated that the shape of the retainer second end 26 may be spherical, square, or rectangular, among other shapes.
[0037] The plank 14 includes a generally linear plank body 28 including an plank top surface 30 , plank bottom surface 32 , and two plank edges 34 . In an example, the plank 14 is a deck board. The plank 14 and receiver 12 may be independently made from any of a number of different materials including, but not limited to, aluminum, polyvinyl chloride (PVC), and polypropylene, among others.
[0038] The plank top surface 30 may be convex such that rain and water run off the plank edges 34 . The plank 14 also includes a set of arms 36 extending perpendicular from the plank bottom surface 32 , wherein each set of arms 36 includes two arms 38 . Each arm 38 includes an arm first end 40 and an arm second end 42 , wherein the arm first end 40 extends from the plank bottom surface 32 .
[0039] As shown in FIG. 3 , the arm second end 42 includes a tab 44 extending parallel to the plank body 28 . Within a set of arms 36 , the two tabs 44 of separate arms 38 may be pointed towards each other. The tab 44 may include a tab end 54 that is tapered. The tapered shape of the tab end 54 may facilitate a user in snapping the plank 14 into place around the retainer 22 . Of course, it is contemplated the tab end 54 may be any suitable shape for facilitating temporarily locking the tab 44 around the retainer groove 48 . For example, the tab end 54 may be round.
[0040] The retainer first end 24 is configured to receive the tabs 44 of the set of arms 36 . For example, the retainer first end 24 may include a retainer groove 48 on each side of the retainer 22 for receiving the tabs 44 of a set of arms 36 .
[0041] When the tabs 44 of the arms 38 are engaged with the retainer 22 of the receiver 12 , the arms 38 maintain a space 46 between the receiver top surface 18 and the plank bottom surface 32 . In an example, the system 10 may further include at least one fastener 52 configured to connect the receiver 12 to a deck joist. The fastener 52 may be any suitable fastener 52 that connects the receiver to structure, such as a deck joist. For example, the fastener 52 may be a screw, nail, clamp, staple, latch, pin, or anchor, among others.
[0042] As shown in FIG. 2 , at least a portion of the fastener 52 resides in a portion of the space 46 between the receiver top surface 18 and the plank bottom surface 20 . For example, when the fastener 52 is a screw, the head of the screw may reside in the space 46 between the receiver top surface 18 and the plank bottom surface 32 .
[0043] As shown in FIG. 3 , each plank edge 34 may include an arm 38 extending from the plank bottom surface 32 , wherein the arm second end 42 includes a tab 44 extending parallel to the plank body 28 . In addition, the arm second end 42 may include a point 50 to enable a continuous drip from the plank 14 . For example, the point 50 may be located on a corner between the arm 38 and the tab 44 . As shown in FIG. 3 , the plank edge 34 may include a corner between the arm 38 and the tab 44 , wherein a portion of the corner is a void 68 to allow water drainage from the plank edges 34 .
[0044] In another embodiment, the system 10 includes a receiver 12 , a plank 14 , and a deck board 56 . Similarly to the receiver 12 and plank 14 , the deck board 56 may be made from any of a number of different materials including, but not limited to, aluminum, polyvinyl chloride (PVC), and polypropylene, among others. As shown in FIG. 4 , the plank 14 removeably attaches to the retainers 22 of the receiver 12 . In addition, the deck board 56 removeably attaches to the plank 14 , such that the deck board 56 conceals the plank 14 from view.
[0045] As shown in FIG. 6 , the deck board 56 may include a deck board body 58 including a board bottom surface 62 , a board top surface 60 , and board ends 64 . The deck board body 58 is configured to mate with the plank 14 . For example, the deck board ends 64 may include a board groove 66 for receiving the plank edges 34 .
[0046] In contrast to the example in FIG. 3 , the example of the plank 14 in FIG. 5 does not include arms 38 extending from the plank edges 34 . As a result, the plank edges 34 may be positioned within the board grooves 66 of the deck board 58 . The plank edges 34 may be snapped, slid, or otherwise removeably attached to the deck board 58 .
[0047] In another example, the deck board ends 64 include a point 50 to enable a continuous drip from the deck boards 56 . As shown in FIG. 6 , the deck board ends 34 may include a corner that includes the point 50 . The corner may further include a void 68 that allows for proper drainage of the water.
[0048] It should be noted that various changes and modifications to the embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. For example, various embodiments of the method and portable electronic device may be provided based on various combinations of the features and functions from the subject matter provided herein. | The present disclosure provides a decking system including a receiver and deck plank, wherein the plank removeably connects to receiver for installation. For example, the receiver may provide a snap lock function that secures and automatically spaces the deck planks on the receiver, which is fastened to a deck joist. In addition, the system is designed to conceal fasteners used to attach the system to the deck joist. | 4 |
TECHNICAL FIELD
The present invention relates to an ignition system arrangement for an ammunition-bearing unit, for example a unit in the form of a shell or missile. The ignition system is in this case of the type which comprises casings which establish electrical contact in the event of deformation caused by striking a target. The ignition system also comprises a unit which detects when electrical contact is established and which sends an initiation signal or trigger signal to the charge (ignition system) of the ammunition-bearing unit as a function of the electrical contact established.
BACKGROUND OF THE INVENTION
It is known to design ignition systems for antitank shells and missiles by arranging a twin casing of electrically conductive material in the nose of the shell or of the missile. The twin casing is surrounded, if appropriate, by a protective envelope. The operating principle is that when the envelope is deformed and the twin casing lying inside it (or possibly unprotected) is deformed, an electrical contact is established between the two parts of the twin casing. This contact is utilized for triggering the ignition system of the shell or of the missile.
The invention is preferably used in ammunition for combating tanks. As means of defense against shells and missiles of the type in question, the tanks can use warheads which expel splinters in the direction of the shell or the missile. The approaching shell or missile is exposed to a cluster of splinters when it is located relatively close to the tank. The purpose of the splinters is either to directly initiate the explosive of the shell or of the missile, or to initiate the shell or missile ignition system by means of a modest investment in terms of material volume, velocity, money and technical sophistication. There is therefore a need for making the approaching shell or missile as insensitive as possible to the said splinters, so that the shell or the missile reaches its target and is triggered there.
SUMMARY OF THE INVENTION
The main aim of the present invention is to propose an arrangement which solves the problems which have been mentioned above. In the present invention, the contact-establishing casings are at least three in number, and the detecting unit is arranged to detect the time difference between the successive contacts established by the casings upon deformation. A further embodiment is that the unit generates the initiation signal or the trigger signal only if the time difference exceeds a selected value.
In one proposed embodiment, a triple casing is provided in which the middle casing is equipped with electrical contact material on both of its sides. A first contact is, in this case, intended to be established between the inner side of the outer casing and the outer side of the middle casing, or between the inner side of the middle casing and the outer side of the inner casing. A second contact can be established between the inner side of the middle casing and the outer side of the inner casing, or, respectively, between the inner side of the outer casing and the outer side of the middle casing.
Contact is usually first made between the inner side of the outer casing and the outer side of the middle casing.
A timing member can be included and can be triggered when the first electrical contact is established. The timing member causes generation of the initiation signal or equivalent signal if a predetermined time elapes after the first contact is established. In the case where the second electrical contact is established within the predetermined period of time, the timing member discontinues its time measurement, and no initiation signal or trigger signal is generated from the timing member.
In one embodiment, the detecting member can calculate the impact velocity, when a deformation occurs, with the aid of the measured time difference between the first and second contacts established, and the distances between the casings. In the case where the calculated velocity is less than the maximum velocity of the ammunition-bearing unit with a certain increment, or another velocity determined or calculated in some way, the detecting unit generates the initiation signal or trigger signal. If, in contrast, the calculated velocity exceeds the maximum velocity of the ammunition-bearing unit with the same increment, the detecting unit does not generate any initiation signal or trigger signal.
In one embodiment, the detecting unit also operates with an upper time limit. If contact is established in the ammunition-bearing unit's trajectory at a distance before the target, and the calculated time after the first contact is established exceeds an upper value, the triple casing function is disengaged and a twin casing function (which can be conventional) is engaged, i.e. two remaining casings of the triple casing function as twin casing.
In a further embodiment, one or more casings of the triple casings can comprise sections which are constructed using contact material and which are insulated from one another. Each section can establish an individual electrical contact which can be registered or can be distinguished by the detecting unit. With the aid of the sections, vulnerability to approaching splinters is reduced to an even greater extent. The detecting unit can be made to ignore contacts established by individual sections during the trajectory of the missile or of the shell. The triggering condition or triggering conditions can be altered successively during the ammunition unit's approach to the target depending on whether it is exposed to splinter attack. In a further embodiment, the triple casing arrangement is included in a combination with a further ignition system which can be initiated by shock waves in the casing or frame of the unit.
With the aid of what has been proposed above, a structure with a triple casing can utilize the times at which short-circuiting of the casings occurs as a type of velocity indicator. Short-circuits which indicate impact velocities greater than a selected/specific velocity of the shell in its trajectory can be ignored. It is possible in this context to start from the maximum velocity, or to perform some estimation, in order to arrive at a better value for the velocity than the maximum value. In certain known missile systems it is possible to obtain from automatic guidance controls and the like a velocity value which is appropriate for the circumstances. The upper margin chosen is, in this case, greater the more uncertain the value of the actual velocity.
A triple casing is designed mechanically in a similar way to a conventional twin casing. The triple casing can thus be used to discriminate between splinter hits and target impact. The invention is also concerned in making the shell or the missile function upon target impact even in the event of one or more splinter hits short-circuiting the connection between two casings or between all three casings. In this context it is possible to have the triple casing sectioned in accordance with the above. The advantage of this is that in addition to the triple casing being able to distinguish between splinter hits and target impact, the triple casing is capable of triggering the shell's warhead, even when a section has already been short-circuited. The logics system of the shell can be made to successively disengage sections which have been penetrated and short-circuited by splinters. The requirement for triggering of the warhead can thus be altered successively, by which means the function of the ignition system is only gradually altered to the extent that in some cases it takes longer for the shell or equivalent to be triggered after striking the target.
One way of making the shell even more resistant to attack by splinters is to coordinate an ignition system with triple casing, and sectioning of one or more of the casings, with an ignition system which detects shock waves in the casing or frame of the shell. These ignition systems are often placed far back in the shell and are therefore well protected against attack, although they can be activated by shock waves which are generated by splinters striking the shell. The logic in a shell with triple casing or sectioned triple casing can also be constructed in such a way that, in the event of damage to the multiple casing system, a shock wave-detecting system will be connected. This system will not be able to discriminate between splinter hits and target impact, but it can be used as a back-up when the ordinary ignition system has been rendered non-operational by being fired on, for example because too many sections have been penetrated by splinters.
BRIEF DESCRIPTION OF THE FIGURES
A presently proposed embodiment of an arrangement according to the invention will be described hereinbelow, with reference being made at the same time to the attached drawing in which:
FIG. 1 shows, in longitudinal section, the front parts of an ammunition-bearing unit with an ignition system comprising a triple casing,
FIG. 2 shows, in a perspective view, parts of a casing which have metal contact surfaces forming sections which are electrically insulated from one another, and
FIG. 3 shows, in circuit diagram form, the function of the triple casing according to FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, reference number 1 designates the front parts of an ammunition-bearing unit. The unit comprises a triple casing arrangement with casings 2, 3 and 4. The outer casing 2 has a shape which is determined by the requirements in respect of air resistance, firing conditions, ammunition type, etc. In the example illustrated, the two casings 3 and 4 lying inside have a shape in which they run substantially parallel to the shape of the outer casing. The three casings are electrically conductive, and contact between them occurs when they are deformed or short-circuited in another way. In certain applications, insulation between the casings is guaranteed by having layers of insulating material between the casings. For reasons relating to strength, the inner casings can be made of insulating material, for example, glass-fiber reinforced plastic on which contact material linings are arranged. Contact can therefore be established between the inner surface of the outer casing 2 and the outer surface of the middle casing 3, and between the inner surface of the middle casing 3 and the outer surface of the inner casing 4. The wires can be drawn from the triple casing in a known manner se, so that the envelope of the shell can constitute a first conductor, while insulated cables or wires 5 and 6 are guided, in the example illustrated, through the inside of the warhead to the ignition system. In certain designs, for example in missiles, one or more wires can be arranged on the outside of the body of the missile or equivalent.
In one embodiment, the supporting inner casings are secured on a sleeve 7 in the interior of the shell, and the metal linings of the supporting casings are finished such that they do not make contact with the said sleeve. The conductors 5 and 6 are connected to a detecting unit 8 which is placed in the unit 1 and which is additionally connected to the conductive frame via a conductor 9. As a result of the said contacts which are established, the detecting unit will generate an initiation signal i1 to the charge of the ammunition-bearing unit, which charge is symbolized by 10. The structure of the unit 1 may be of a known type and will not be described in any great detail here. One or more of the casings 2, 3, 4 can support contact material linings which are designed as sections 11, 12, 13, etc. according to FIG. 2. The sections are insulated from one another and in this case there are individual wires drawn from the sections to the unit 8. The distances between the casings are indicated by a, b in FIG. 1. The distances between the sections 11, 12, 13 in FIG. 2 are indicated by c and d. Instead of having the envelope of the shell constitute the first conductor in the manner described above, this first conductor can be formed, like the conductors 5 and 6, by an insulated cable or wire.
In FIG. 3, the flight direction of the unit 1' is indicated by the arrow 14. A splinter fired at the unit 1' is shown by 15, and the direction of the splinter is indicated by 16.
On target impact, which is often relatively slow (200-300 m/s), the nose of the shell or of the unit will probably be deformed gradually. At a time t1 shown in FIG. 3, short-circuiting occurs between the outer casing 2' and the middle casing 3'. At a time t2, short-circuiting occurs between the two inner casings 3' and 4'. The time t3 indicates the time when the splinter passes through the inner casing. The time interval between the short-circuits can be calculated based on the velocity of the shell relative to the target and the distance between the casings. Assuming a shell velocity of 300 m/s and a distance a, b of 2 mm between the casings, short-circuiting between the casings 2' and 3' will occur about 6.7 microseconds after impact, and short-circuiting between the casings 3' and 4' will occur after a further 6.7 microseconds. The time between the short circuits is 6.7 microseconds. In one illustrative embodiment, the unit 8' is arranged or programmed to initiate the shell warhead only if the time between the short circuits is longer than a specified value, for example 5 microseconds. A safety margin is thus obtained by means of the last-mentioned time being shorter than the first-mentioned time. The time specifications, distances etc. chosen can be different in different constructions. Typically, the time period between the first and second contacts is in a range of 4-40 microseconds.
If a counterattacking means, for example the said splinter 15, hits the shell, the former will normally have a considerably greater velocity than the shell itself, typically 1000 m/s, to which is added the shell's own velocity. Splinters (and secondary splinters) will in most cases be able to cause electrical contact to be established if they exceed the measurements a and b according to FIG. 1. Thus, for example, splinters, for instance the splinter 15, can generate two short-circuits with shorter time intervals than approximately 2 microseconds. The margin between these two microseconds and the previously mentioned 6.7 microseconds is great, and discrimination between target and splinter can be effected relatively easily with the aid of the detecting unit or logics 8'.
The unit 8, 8' can comprise a timing member which measures the time between the first and second contacts being established. Since the distances a, b are known, the velocity on target impact and on collision with approaching splinters can also be calculated by the unit and related to the maximum velocity of the shell. Velocities which are below a certain predetermined shell velocity result in generation of the initiation signal i1' from the unit 8'. If the velocity is greater than the shell velocity, the signal i1' is not generated. Safety margins can in this case be easily implemented in the unit 8'.
Since the ignition system will comprise a triple casing, it may happen that a fragment/splinter piece remains in the triple casing and thus short-circuits either the inner or the outer circuit. The logic in the system can, in this case, ignore this short-circuit if it persists for a relatively long time, for example a few milliseconds, after which the ignition system can function as a twin casing with the remaining open, unaffected circuit (the twin casing). It may also happen that both the contacts are short-circuited. The shell or missile is thereafter without an ignition system. However, if the ignition system is designed with sectioned casings according to FIG. 2, the logic system 8' of the shell will be able to cope with individual splinter hits of this type too.
In FIG. 1, a symbolically represented target is indicated by 17.
The construction of the detecting unit 8, 8' in conjunction with a sectioned casing, is described in Swedish patent number SE 9501603 (ignition system arrangement) corresponding to U.S. patent application Ser. No. 08/945,711, incorporated herein by reference, which was filed on the same day by the same Applicant.
The invention is not limited to the embodiment which has been shown hereinabove by way of example, but can be modified within the scope of the following patent claims and the inventive concept. | An ammunition bearing unit is provided. The unit includes at least three casings. When the ammunition bearing unit strikes a target, the casings are deformed and make successive electrical contacts. A detecting unit is arranged to detect a time difference between the successive electrical contacts created by the deformation of the casings. The detecting unit generates an initiation signal only if the time difference exceeds a selected value. An ignition system sends a signal to a charge as a function of the electrical contacts. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a toxic fluid and vapor handling apparatus. More particularly, the invention pertains to a chemical spill containment system wherein spilled toxic chemicals and vapors are automatically contained and safely removed to prevent contamination.
DESCRIPTION OF THE PRIOR ART
Many industrial systems employ machines that contain and use large quantities of potentially harmful chemicals. These machines often include a variety of elements, such as pumps, stills, filters, condensers, storage tanks, and the like that contain or process significant amounts of toxic chemicals. Those concerned with the use or deployment of such machines, especially for use in populated areas, have long recognized the potential dangers that these machines pose when one or more of their elements ruptures or otherwise fails thereby causing a chemical spill. Manufacturers of such machines, being mindful of these potential hazards, have made great efforts in increasing machine reliability by using some of the most advanced materials and methods in their manufacture. Additionally, the ENVIRONMENTAL PROTECTION AGENCY (EPA) and the OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) have issued numerous regulations that manufacturers and users of such equipment are required to follow. However, in spite of these efforts, chemical spills from ruptured machine parts still occur.
As an important example, in the dry cleaning industry, it has been the general practice to employ large dry cleaning machines that use significant quantities of toxic cleaning fluids. A typical machine might use up to 100 gallons or more of a potentially dangerous chemical such as perchloroethylene or tetrachloroethylene. As is well known, these dry cleaning machines are frequently used in local neighborhoods and shopping centers populated by employees, customers, neighbors, etc. where the effects of a chemical spill may be critical. Again, OSHA and the EPA have published regulations for the dry cleaning industry on what actions must be taken in the event of a chemical spill. These regulations are primarily directed at the elimination of such chemical-spill hazards as improper ventilation; toxic vapors caused by the chemicals being exposed to open flames, sparks and electric circuits; contamination of water systems; and leakage of the spilled chemicals into nearby buildings. Additionally, workers in the dry cleaning field have been warned against the inhalation of vapors from dry cleaning fluids, the prolonged or repeated contact of the liquid with the skin or other body parts, the swallowing of the liquid, and the splashing of the liquid into the eyes. Exposure to a high-vapor concentration of some dry cleaning fluids can cause severe depression of mental functions, respiratory failure and even death. OSHA has recently released standards aimed at protecting workers from exposure to atmospheres having perchloroethylene vapor concentrations greater than 25 parts per million. This concentration can be found in many dry cleaning establishments during normal operation of the dry cleaning machinery. In response to the OSHA standard, some in the industry have proposed that workers routinely use cartridge respirators or masks having an independent air supply. A notification published by the industry for display in establishments using dry cleaning machines that employ perchloroethylene give the following instructions in the event of a spill or leak:
"Evacuate the area, ventilate, and avoid breathing vapors. Dike area to contain spill. Personnel wearing proper protective equipment including air line respirator or self-contained breathing apparatus, with full facepiece, should clean up area by mopping or with absorbent material and place in closed containers for disposal. Avoid contamination of ground and surface waters. Do not flush to sewer".
Additionally, in some geographical areas regulations require that a spill of as little as five gallons of perchloroethylene must be reported to certain organizations such as the local fire and police departments, the sewer and water departments, OSHA, EPA, the National Response Center, etc. Although there has been a long recognized need for a chemical spill containment system for use in the dry cleaning industry and similar industries that use large chemical processing machinery, no practical system for so-doing has yet been devised. The present invention fulfills this need.
SUMMARY OF THE INVENTION
The general purpose of this invention is to provide a chemical spill containment apparatus, for use with large industrial, chemical processing machinery, that operates automatically to detect a spill and responds thereto by trapping and removing the chemical fluids and vapors from the open area adjacent the machinery. To attain this, the present invention contemplates a trough surrounding the base of the machine for trapping the spilled chemical and draining it into a pit in which a pump is located that is automatically engaged to pump the spilled chemical into a closed holding tank. Simultaneously, a vapor detecting device will automatically turn on a ventilation system that will suck vapors from the area of the trough and from an optional isolation tent surrounding the machine and force the vapors through a filter having a bed of charcoal for absorbing the toxic vapors from the air. The filtered air is then vented to the atmosphere. A splash curtain is also used to direct the spilled chemicals into the trough. A substantial portion of the apparatus may be molded as a single unit or as separate sections that may be readily assembled and fixed into a unit at the installation site.
It is, therefore, an object of the present invention to provide a chemical spill containment system.
Another object is the provision of a means for automatically detecting a chemical spill and for taking a plurality of actions to remove the liquid chemical and toxic vapors from the area immediately adjacent the source of the spill.
A further object of the invention is the provision of a means for continuously removing small but significant concentrations of a toxic vapor from the atmosphere adjacent a chemical processing machine during periods of normal operation.
Other objects and many of the attendant advantages of this invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings in which like reference numerals designate like parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a pictorial view partly in section of a preferred embodiment.
FIG. 2 shows a top view with parts broken away of a portion of the device shown in FIG. 1.
FIG. 3 is a section of the device shown in FIG. 2 taken along the lines 3--3 and looking in the direction of the arrows.
FIG. 4 is an elevation in section of a portion of the device including the pit shown in FIG. 1.
FIG. 5 shows a view similar to the view shown in FIG. 1 with parts shown in phantom.
FIG. 6 is a block diagram showing the electrical controls for the preferred embodiment shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is shown a chemical spill containment system 10 having a liquid trapping unit 12 that may be fabricated from plastic, fiberglass or other suitable material. Unit 12 includes an outer wall 14, a top wall 15, a first inner wall 16, a bottom wall 17, and a second inner wall 18. Walls 14-18 form a closed rectangular-shaped trough 36 that surrounds a raised rectangular-shaped pad 20 on which the machine 21 is mounted. Machine 21, shown in phantom lines, represents a dry cleaning machine that includes a front loading door 22 and a chemical storage tank 28. Of course, the present invention may be employed equally as well with other types of machines susceptible to chemical spills as will become evident to those skilled in these arts.
The trapping unit 12 further includes a loading ramp 23 and an adjacent liquid collection receptacle 24 having vertical sidewalls and a bottom in the form of a funnel-shaped pan 25 having a central drainage orifice 26. The unit 12 has an outer horizontal flange 27 extending from the lower edge of wall 14, ramp 23 and the outer wall of receptacle 24. The unit 12 is designed to sit on a reasonably level floor 30 formed from concrete or other suitable material with flange 27 and bottom wall 17 in contact with the floor 30. The flange 27 may be attached to floor 30 by bolts or other fastening means. A grate-receiving ledge 29 is formed at the upper edge of inner walls 16 and 18, and the inner vertical wall of receptacle 24. An inner, horizontal flange 32 extends inwardly from the ledge 29 on the wall 18 and is fixed to form a tight seal with the upper surface of pad 20. Clearly, the trapping unit 12 may be readily molded from a suitable plastic, fiberglass or other like material as a single unit or as a plurality of sections that may be assembled, joined and sealed at the installation site. The walls 14, 15 and 16 form a shell for housing a vapor exhaust conduit 35 that forms a closed loop. Conduit 35 is preferably fixed at appropriate locations to the inner surface of one or more of the walls 14, 15 and 16. At spaced intervals along the conduit 35, apertures are formed in the conduit 35 and the adjacent inner wall 16 to receive the ends of tubes 37. A vapor exhaust pipe 39 is joined to the conduit 35 and passes through wall 15 to a vapor exhaust system 41 having an exhaust fan 43 for forcing vapors from pipe 39 into a carbon bed 45 where toxic vapors are removed by filtering and clean air is vented via vent conduit 47.
The trough 36 and the receptacle 24 are covered by removable grates 50 to form a walkway to permit access to the machine 21. The loading ramp 23, on which a wheeled container may be easily moved, permits easy access to the loading door 22. Grate 50, typically made of several individual pieces for easy installation and removal, is supported by ledge 29.
The bottom wall 17 of trough 36 is pitched at a slight angle towards the location of receptacle 24. As such, the floor 30, on which the bottom wall 17 preferably rests, may also be pitched at this slight angle (FIG. 4). A drainage pipe 52 passes from the lowest point of trough 36 into the receptacle 24. An overflow pipe 53 also extends from trough 36 into receptacle 24 at a location just above the pipe 52 to provide additional drainage in the event that pipe 52 is blocked by debris.
The receptacle 24 is mounted in a pit 54 such that the pan 25 is located below the grade of bottom wall 17. A pump 56 is mounted in pit 54 below the pan 25. A drainage pipe 58 extends between orifice 26 and the input to pump 56. The output of pump 56 is connected by a liquid removal pipe 60 that extends through pan 25 and receptacle 24 to a sealed liquid holding tank 62 for later removal of the spilled chemicals.
A control circuit 75 (FIG. 6) automatically energizes the fan 43, pump 56, emergency equipment such as lights and other alarms 72, and a communication system 79. Additionally, circuit 75 will also shut down the ruptured machine 21 and other equipment that might pose a hazard during a chemical spill. For example, in most situations, such chemicals are susceptible to combustion when exposed to an open flame or other ignition source. Therefore, as indicated by reference character 92 in FIG. 6, the boilers and other types of machinery are shut down immediately upon detection of the chemical spill. Also, the normal building ventilation units which routinely vent and circulate air in the building are also shut down to prevent the escape of any toxic vapors to the atmosphere before cleaning the air in carbon bed 45.
Circuit 75 (FIG. 6) includes connections to the main AC power supply 83. A conventional liquid activated microswitch 85, mounted in drain pipe 58 (FIG. 4), and a conventional ball float switch 87 (FIG. 4), mounted in receptacle 24, are connected in parallel with each other and in series with a relay coil 89 (FIG. 6). Switches 85 and 87 are normally open and together with coil 89 are connected across power supply 83 through a manual on/off switch 90. Coil 89 is coupled to normally closed relay switch 91 and normally open relay switch 88. The main circuits 92 of the machine 21 and other normally-operating equipment that may pose a hazard are connected across the main power supply 83 through switch 91. A conventional normally open, vapor detector switch 93, located in receptacle 24 (FIG. 4), is connected in series with a relay coil 94 that is coupled to normally open latching switch 95. Coil 94 and switch 93 are connected in series with each other and across power supply 83. A conventional AC/DC power source 81 is connected across power supply 83. AC/DC source 81 provides power to the communication system 79 via switch 95. In the event of a power failure at the source 83, the power source 81 will continue to provide sufficient power to system 79 if switch 95 has been closed.
The operation of circuit 75 is as follows: When a chemical spill occurs, it is contemplated that any liquids trapped in trough 36 will drain into the pump 56 via pipe 52, receptacle 24 and pipe 58. The draining liquid will cause the switch 85 to close which will energize relay coil 89 thereby opening switch 91 and closing switch 92. Upon the closing of switch 92, the fan 43 and the pump 56 will be made operative. The pump 56 will pump the draining liquid into the sealed holding tank 62 via pipe 60. The fan 43 will remove air surrounding the trough 36 via tubes 37, conduit 35 and pipe 39. This air will be forced through the carbon bed 45 to remove any toxic vapors before exhausting the clean air into the atmosphere. It is noted here that toxic vapors from industrial chemicals such as dry cleaning chemicals are usually heavier than air and, as such, will normally accumulate at the lower levels of a given area.
The float switch 87 is provided as a backup in the event that there is a failure at the switch 85. To prevent a runaway spill due to a blockage at pump 56 or a power failure or other reason that prevents pump 56 from removing the spilled chemicals, it is contemplated that the volume of the effective portion of trough 36 and receptacle 24 be sufficiently large enough to be able to hold substantially all liquids from any expected chemical spill.
The vapor-operated switch 93 will detect situations in which a predetermined amount of chemical vapor has entered the surrounding atmosphere. Such situations, as mentioned earlier, usually require that certain organizations be notified. It is contemplated in the present invention that the communication system 79 be provided to automatically inform appropriate authorities and government offices over normal telephone lines that a significant chemical spill has occurred. The system 79 may also be used to inform other key management and maintenance personnel in the event of a spill occurring at an unattended machine.
As an optional feature, the system 10 may also include a transparent splash curtain 100 that is suspended by a framework 101 about the top, back and sides of machine 21. The curtain 100, formed from any suitable transparent plastic sheet, has a bottom edge that carries snaps or other like fasteners for securing the curtain 100 to the wall 16 near the upper edge so that chemicals spraying from machine 21 will be directed into trough 36. The rear and side walls of curtain 100 may have door flaps or other means for permitting easy access to the machine 21.
As an additional feature, the system 10 may be readily combined with an isolation tent 110 that is suspended by a framework 111 to cover the top, front, back and sides of the system 10. Like splash curtain 100, the tent 110 may be constructed of flexible transparent plastic. The bottom edges of tent 110 rest on the outside of the trapping unit 12 just above flange 27. The tent 110 is fixed to the lower portion of wall 14 (FIG. 3) by snaps 112 or other suitable means. The side wall of tent 110 in the area of the ramp 23 has an entrance opening covered by a plurality of transparent plastic strips 118 that are joined to the tent 110 at their upper ends and are otherwise permitted to hang free in a contiguous or overlapping fashion with each other to prevent the escape of vapors while permitting access to the ramp 23 by forming a partial seal at the entrance opening.
A carbon sniffer 115, having a pipe 117 connected to select locations of the tent 110 just above the level of wall 15, includes an exhaust fan 120 for removing air from tent 110 during normal operation of the machine 21. Fresh air is supplied to the tent 110 by a fresh air fan 122. The isolation tent 110 and sniffer 115 continuously remove the air surrounding machine 21 near the lower levels and replaces the air with fresh air via fan 122. As such, tent 110, sniffer 115 and fan 122 cooperate with the system 10 to continuously clean the atmosphere during normal operation of the machine 21.
It should be understood, of course, that the foregoing disclosure relates to only a preferred embodiment of the invention and that numerous modifications as alterations may be made therein without departing from the spirit and the scope of the invention as set forth in the appended claims. | A trough surrounding the base of a machine for trapping the spilled chemical and draining it into a pit in which a pump is located that is automatically engaged to pump the spilled chemical into a closed holding tank. A vapor detecting device will, upon the detection of toxic vapors, automatically turn on a ventilation system that will remove vapors from the area of the trough and from an optional isolation tent surrounding the machine and force the vapors through a filter having a bed of charcoal for absorbing the toxic vapors from the air. The filtered air is then vented to the atmosphere. A splash curtain is also used to direct the spilled chemicals into the trough. A substantial portion of the apparatus may be molded as a single unit or as separate sections that may be readily assembled and fixed into a unit at the installation site. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for manufacturing a tubular filter from a non-woven fabric web, and the resulting product.
Filters having non-woven fabric structures are presently utilized for filtering materials such as paint and various chemicals. Such filters are especially useful for filtering enamels to remove gel particles or unmilled paint particles therefrom.
The term "non-woven fabric web" as herein employed is intended to mean a needled felt web formed of relatively short (up to several inches in length) mechanically interlocked fibers or strands having various relative orientations.
Commonly utilized filters of the aforementioned type comprise a cylindrical perforated core of resin impregnated paper wire mesh, or perforated steel upon which has been deposited a non-woven fabric web. A cylindrical wire tube or tubes to which a vacuum is applied, is immersed in a water slurry of fibers and water emulsified resins (as a binder). The wire tubes are slowly turned while in the slurry and a deposit of fiber and binder is formed. The formed fibrous cylinder is next transferred to an oven to drive off the water and cure the resin binder.
Disadvantages of the aforementioned prior art process and resulting filter are (i) a tremendous amount of water has to be driven off in the drying process so the resin can be cured, requiring a great deal of energy; (ii) the process is relatively "messy", and unsuitable for use in manufacturing small quantities of special purpose filters; and (iii) the fibers of the resulting filter are not randomly oriented, as may be desirable in certain applications, but due to the rotation of the fiberglass core are oriented in a generally annular direction.
In addition, special prior treatments to the felts such as singeing, glazing, calendaring, and fabric scrim reinforcement cannot be performed in conjunction with said prior art process.
Accordingly, an object of the present invention is to provide a tubular non-woven fabric filter which overcomes the aforementioned disadvantages, and a process and apparatus for manufacturing the same.
SUMMARY OF THE INVENTION
As herein described there is provided a process for manufacturing a tubular filter from a non-woven fabric web, comprising the steps of:
Providing a cylindrical mandrel, with a cylindrical guide sleeve coaxial with and surrounding at least a portion of the length of said mandrel; drawing said web onto said mandrel between said sleeve and said mandrel to form said web into a tubular shape with the sides of said web in abutting relationship; and transversely penetrating said abutting sides of said web with at least one reciprocating needle to provide sufficient penetrations per unit of length of said web to form a butt joint between said sides of said web to retain said web in said tubular shape.
According to a related aspect of the invention, there is also provided an apparatus for manufacturing a tubular filter from a non-woven fabric web, comprising a cylindrical mandrel; a guide sleeve coaxial with and surrounding at least a portion of the length of said mandrel; means for drawing said web onto said mandrel between said sleeve and said mandrel to form said web into a tubular shape with the sides of said web in abutting relationship; at least one needle having a plurality of barbed portions; means for holding said needle in a first needling position extending transversely of said mandrel and sleeve through the space therebetween; and means for transversely reciprocating said needle holding means.
The present invention also provides an improved tubular filter manufactured by the aforementioned process.
DETAILED DESCRIPTION
The invention will be more clearly understood by reference to the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a plan view of a non-woven fabric web utilized in practicing the invention;
FIG. 2 is an end view of the web shown in FIG. 1;
FIG. 3 is an end view of a tubular filter according to a first embodiment of the invention;
FIG. 4 is an end view of a tubular filter according to a second embodiment of the invention;
FIG. 5 is an isometric view showing apparatus employed in practicing the invention;
FIG. 6 is a cross-sectional view of part of the apparatus shown in FIG. 5, taken in the direction 6--6;
FIG. 7 shows an isometric view of the portion of the apparatus of FIG. 5 which performs the tube forming and needling operation of the process of the invention;
FIG. 8 shows a cross-sectional view of the apparatus of FIG. 7, taken along the cutting plane 8--8 therein as shown in FIGS. 6 and 7;
FIG. 9 shows the apparatus of FIG. 7, modified to manufacture tubular filters according to the second embodiment of the invention;
FIG. 10 shows a cross-sectional view of the apparatus of FIG. 9 taken along the cutting plane 10 (similar to 8--8 of FIG. 6) therein; and
FIG. 11 is a side view of one of the barbed needles employed in the aforementioned apparatus.
The non-woven fabric web 12 as shown in FIGS. 1 and 2 comprises a multiplicity of randomly oriented individual fibers which are bonded together, either by means of a separate bonding agent or by fusing together the fibers. Preferably, in practicing the invention, the individual fibers of the web 12 are fused together to form the web structure, and are relatively coarse.
Preferably the fibers comprising the web 12 should have a coarseness of 15 denier or more. Fibers in the range of 25 to 40 denier are preferred for most applications. In the particular embodiment of the invention which was actually manufactured, it was found that 25 denier fibers with a staple or fiber length of the order of 3 inches gave good results.
Preferred materials for the non-woven web 12 are polyester fibers such as, but not limited to, rayon and dacron. In the aforementioned preferred embodiment, 25 denier dacron was employed.
If desired, the non-woven fabric web 12 may comprise two or more adjacent layers. These layers may be of the same denier, or alternatively may be of progressively finer denier, with the web being oriented so that when it is formed into a tubular shape the innermost layer has the finest denier (i.e.) in arrangements where the fluid to be filtered is introduced to the exterior surface of the resulting tubular filter). Such an arrangement provides a progressive filtering action, so that the coarsest particles are removed by the outer layer, and progressively finer particles are removed by the inner layers.
As shown in FIG. 2, it has been found that an improved filter structure results when the sides of the web 12 are chamfered so that the web surface which becomes the outer surface of the tubular filter has a width greater than that of the web surface which becomes the inner surface of the filter, when the web is bent in the direction of the arrows 13 to form said tubular structure. Preferably, the acute angle at which the sides of the web 12 are chamfered may be on the order of 30°.
FIG. 3 shows a tubular filter produced according to the present invention, in which the web 12 has been formed into a tubular structure 14 having a butt joint 15 between the opposite sides 16 and 17 of the web 12. In the bulk of the tubular filter 14, the fibers comprising the same are randomly oriented, as of course are the fibers comprising the web 12 utilized in forming said tubular filter. However, in the vicinity of the butt joint 15, the random orientation of the fibers has been disturbed by a needling action produced by the apparatus hereafter described, so that the fibers on the side 16 of the web 12 have become intertwined with the fibers on the side 17 thereof, thus effectively bonding said sides together to form the butt joint 15.
The tubular filter 18 shown in FIG. 4 comprises an inner layer 19 and an outer layer 20, said layers having respective butt joints 21 and 22. Each of the layers 19 and 20 comprises a non-woven fabric structure of the type previously described with respect to the web 12. Each of the butt joints 21 and 22 is similar in structure to the butt joint 15 of the tubular filter 14.
The two-layered tubular filter 18 is formed from a web 12 having two layers, which may preferably be of different denier as previously mentioned, i.e., with the layer 19 having the least denier, for greatest fineness. To make the tubular filter 18, a similar process to that employed in making the filter 14 is employed, except that in the case of the filter 18 the two layers 19 and 20 of the web utilized to form the filter 18 are separated and formed in such a manner that the butt joints 21 and 22 are disposed at different rotational positions (180° apart in FIG. 4) about the periphery of the tubular filter 18. This arrangement provides improved strength.
Typically, the web 12, and the resulting tubular filters 14 and 18, may have a thickness in the range of 0.25 to 1.0 inches.
The apparatus 23 for manufacturing the tubular filters 14 and 18 from the web 12 is shown in FIG. 5, and comprises (i) a support structure 24, (ii) a drive motor 25, (iii) a drive motor control unit 26, (iv) a pair of rollers 27 driven by the motor 25 through a pulley 28 and a belt 29, (v) a tube shaping and needling unit 30, (vi) a needle reciprocating motor 31, (see FIGS. 6, 8 and 10), and (vii) a linkage 32 coupling the needle reciprocating motor 31 to the forming and needling device 30.
Referring again to FIG. 5, a web 12 having a width substantially equal to the circumference of the tube 14 to be formed therefrom, is initially fed by hand through the forming and needling device 30 and between the rollers 27 in the direction of the arrows 33. This initial hand feeding step is readily accomplished by cutting the lead end of the web 12 so as to form a relatively narrow strip therefrom, and feeding this narrow strip through the device 30 and between the rollers 27.
Once the initial feeding step is completed, the rollers 27 are driven by the motor 25 at a speed determined by the control unit 26 to draw the web 12 through the forming and needling unit 30.
As the web 12 is drawn through the forming and needling unit 30, it is shaped into a tubular form and the then abutting sides 16 and 17 thereof are needled together by the device 30 to form the butt joint 15. The amplitude of the strokes of the needles of the forming and needling device 30 is determined by the mechanical linkage between said device and the needle drive motor 31, and the rate at which the needles reciprocate is determined by the control unit 34, which controls the speed of the motor 31.
As shown more clearly in FIG. 7, the forming and needling device 30 comprises a base plate 35, two blocks 36 and 37 axially displaced from each other and having aligned holes therein, and a cylindrical shaping sleeve 38 disposed within and extending between said holes and having its outer periphery thereof secured to said blocks.
As more clearly shown in FIG. 6, a cylindrical mandrel 39 is secured to a vertical support 40 and cantilevered therefrom to extend coaxially through the sleeve 38. The support 40, in turn, is secured to a horizontal member 41 which is disposed above a support plate 42. Blocks 43 maintain the desired separation between the members 41 and 42.
Also disposed on the plate 35 are four rod support blocks 44, 45, 46 and 47. Support rods 48, 49, 50 and 51 extend from respective ones of these support blocks to corresponding support holes in the blocks 36 and 37. That is, the rod 48 extends between the block 36 and support 44; rod 49 extends between block 37 and support 45; rod 50 extends between block 36 and support 46; and rod 51 extends between block 37 and support 47.
A first needle holder 52 is slidably mounted on the rods 48 and 49 by means of journaled bearings 53 and 54 respectively. Similarly, a second needle holder 55 is slidably mounted to rods 50 and 51 by journaled bearings 56 and 57 respectively.
Extending transversely of the mandrel 39 and sleeve 38 through corresponding holes in said sleeve are a plurality of needles 58, each having a structure as shown in FIG. 11. Each of the needles 58 has a plurality of barbed portions 59 thereon, each of said barbed portions 59 having a length L which may typically be on the order of 0.25 inch. Each of the needles 58 has a bent end part 60 which may be inserted in a corresponding hole or slot of one of the holders 52 and 55 and secured therein with a set screw or other locking device to secure said needle in position.
As shown in FIG. 7, four of the needles 58 extend from the holder 52 through holes in the sleeve 38 into the space between said sleeve and the mandrel 39. Although not visible in FIG. 7, in similar fashion, four additional needles 58 extend from the holder 55 through corresponding holes in the sleeve 38, into said space between said mandrel and sleeve. The needles extending from the holder 52 alternate in staggered fashion with the needles extending from the holder 55.
A drive plate 61 (see FIGS. 6 and 8) is disposed above the plate 35 and between the blocks 36 and 37. The drive plate 61 is secured to the bottom surfaces of the needle holders 52 and 55. A bracket 62 is secured to the bottom surface of the drive plate 61 and extends downwardly through a hole 63 in the plate 35.
One end of the link 32 is pivotally secured to a disk 64 by means of a pivot pin 65. The other end of the link 32 is pivotally secured to the bracket 62 by means of a pivot pin 66. The disk 64 is secured to the shaft 67 of the motor 31 for rotation therewith.
The above described connection between the bracket 62 and the shaft 67 of the motor 31 results in reciprocating movement in the direction indicated by the arrows 68, i.e., along the direction of the rods 48, 49, 50 and 51 or transversely of the mandrel 39 and sleeve 38, of the drive plate 61, needle holders 52 and 55, and needles 58 secured thereto when the motor 31 is operated to cause rotation of its shaft 67. The amplitude of this reciprocating movement is determined by the distance between the shaft 67 and pin 65, and the angle between the link 32 and bracket 62.
Preferably, the amplitude of reciprocation of the holders 52 and 55 and needles 58 mounted thereon, should be at least equal to 2L, i.e., twice the length of one of the barbed portions 59 of the needles 58. In practice, good results have been achieved with reciprocation amplitudes on the order of 2 to 3 times the length of said barbed portions. For example, utilizing needles 58 having barbed portions approximately 0.25 inch in length, good results have been realized with reciprocation amplitudes in the range of 0.50 to 0.75 inch.
While the rate of reciprocation of the holders 52 and 55 and associated needles 58 is not critical, this rate should be sufficiently high so that a desired number of needle penetrations of the web being processed can be achieved per unit length, with an acceptable rate of linear feed of the web material. However, if the reciprocation rate is excessively high, an unacceptable degree of breakage of the fibers results, so that the butt joint formed thereby is relatively weak.
Preferably, the web 12 should be fed through the space between the mandrel 39 and sleeve 38 in such a manner, and with such a reciprocation speed of the drive plate 61, so that the number of needle penetrations of said web is in the range of 200 to 800 penetrations per linear inch of web length. Optimum results have been achieved with said number of penetrations being on the order of 450 per unit length.
The modified version of the forming and needling unit 30 required to manufacture a filter of the type 18 shown in FIG. 4, is shown as 30a in FIGS. 9 and 10. This modified unit is identical to the unit 30, except that a first additional needle holder 69 and a second additional needle holder 70 are provided to produce the desired needling action on the additional butt joint of the filter 18. Each of the holders 69 and 70 has a corresponding plurality (4 in the preferred embodiment) of the needles 58 extending therefrom. The holder 69 is slidably mounted on support rods 71 and 72 extending diagonally upward from the blocks 36 and 37 respectively, by means of respective journaled bearings 73 and 74. Similarly, the holder 70 is slidably mounted on support rods 75 and 76 extending diagonally upward from the blocks 36 and 37 respectively, by means of respective journaled bearings 77 and 78.
Reciprocating movement of the holders 69 and 70 in synchronism with movement of the holders 52 and 55 is provided by the connecting links 79, 80, 81 and 82. The links 79 and 81 connect the holders 70 and 52 together, for coordinated sliding movement, while the links 80 and 82 connect the holders 69 and 55 together for coordinated movement. That is, when the drive plate 61 moves to the right, the holders 52 and 55 also move to the right, causing the holder 70 to move diagonally down toward the right and the holder 69 to move diagonally up toward the right. The net effect of these movements is to cause the needles secured to the holders 52 and 69 to partially withdraw from the interior space between the mandrel 39 and sleeve 38, while at the same time causing the holders 55 and 70 to extend further into said interior space. When the drive plate 61 is reciprocated in the opposite direction, i.e., toward the left, as seen for example in FIG. 7, opposite movements of said holders and their associated needles occur.
The manner in which the apparatus described above operates in accordance with the invention will best be understood by reference to FIGS. 6 through 10.
As shown in FIG. 6, the web 12 is fed over the mandrel 39 and is drawn into the space between the mandrel 39 and sleeve 38 by the drive action of the rollers 27. The web 12 is initially oriented so that as it is formed into a tubular shape by the action of the mandrel 39 and cooperating sleeve 38, the butt joint formed between the sides of the web is centrally situated below the mandrel 39. It has been found that once the feeding process is started, there is no appreciable rotation of the web, i.e., the butt joint remains situated centrally below the mandrel 39.
As the web 12 is drawn through the space between the mandrel 39 and sleeve 38, the needles 58 of the holders 52 and 55 move in reciprocating fashion through the region of the butt joint between the sides of the web to cause movement of the web fibers in the vicinity of said joint, thereby securing the sides 16 and 17 of the web 12 together at said joint, thus retaining the web 12 in tubular shape 14 as shown in FIG. 3.
As is evident in FIG. 6, preferably the needles 58 are situated at different distances from the mandrel 39, so as to provide the desired needling action throughout the cross section of the butt joint 15 (see FIG. 3) formed by said needling action.
If desired, after the tubular filter 14 is formed, it may be impregnated with a bonding agent such as a thermoplastic resin, in known fashion, for additional structural strength and stability.
When it is desired to form the two-layered tubular filter 18, the modified forming and needling unit 30a shown in FIGS. 9 and 10 is employed. As indicated in FIG. 6, the layers 19 and 20 of the web being fed into the unit 30a are separated, with the web layer 20 being fed between the plates 41 and 42 toward the bottom portion of the mandrel 39, and the layer 19 being fed toward the upper portion of the mandrel 39. The action between these layers and the mandrel 39 and sleeve 38 results in the inner layer 19 being shaped into a tubular form with the sides thereof in abutment below the center line of the mandrel 39, and formation of the outer layer 20 into a tubular shape with the sides thereof in abutment above the center line of the mandrel 39. That is, the layers 19 and 20 are formed into contiguous tubular shapes with their sides in abutment at regions rotationally displaced 180° from each other.
As is evident from FIG. 10, as the layers 19 and 20 are drawn through the forming and needling device 30a by the rollers 27, the needles 58 secured to the lower holders 52 and 55 provide a needling action through the abutting sides of the inner layer 19 to form the butt joint 21 (see FIG. 4). At the same time, the needling action of the needles 58 of the upper holders 69 and 70 causes said needles to extend through the abutting sides of the outer layer 20 to form the butt joint 22 (see FIG. 4).
In similar fashion, additional reciprocating needle holders and associated needles could be provided to form a plurality of butt joints in a plurality of layers of a web, i.e., the two layered structure 18 shown in FIG. 4 could be extended to a structure having additional layers.
As previously pointed out, the resulting tubular filter structure is different from prior art structures, in that the fibers thereof have a random orientation which is disturbed only in the region of the aforementioned butt joint(s). It is possible that there are other differences between the resulting structure and that produced by prior art devices. However, such differences are difficult to define except by defining Applicants structure in terms of that which results by carrying out the process described above.
In cases where the fluid to be filtered is introduced into the interior rather than the exterior of a multi-layered filter having layers of different coarseness, the coarsest layer should of course be the innermost layer and the finest layer should be the outermost layer.
By the term "barbed needle" as employed herein is meant any needle having lateral protuberances which is capable of effecting an intertwining of the web fibers to form a butt joint as previously described. | A non-woven fabric web is converted to a tubular shape by forming the web between a cylindrical mandrel and surrounding sleeve, and passing reciprocating barbed needles through the region where the sides of the web abut each other, to form a butt joint thereat. The apparatus includes a pair of rollers for drawing the tubular shaped web between the mandrel and sleeve, as well as a motor and control circuit for operating the reciprocating needles. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a window guard for preventing unauthorized ingress through a window and more particularly to a window guard having a new and novel, adjustable mounting member for anchoring the guard to a window frame and for interrupting the path of travel of one of the window sashes after it has been opened a predetermined amount.
Unauthorized access to homes is frequently obtained by a burglar who breaks a glass pane mounted in a window sash. The burglar then slips his hand through the broken window to unlock the window sash, and then merely slides the window sash to an open position. To inhibit burglary, one could cover the entire outside of the window with expanded metal, but such a construction is not aesthetic. Moreover, a complete covering of the window with expanded metal seriously inhibits cleaning of the outsides of the window.
Not all windows are of the same dimensions and thus it is important that any such window guard be adjustable to accomodate such varying size windows. Accordingly, it is an object of the present invention to provide a window guard having new and novel extensible mounts for mounting the guard on the window frame.
It is another object of the present invention to provide a window guard for a window including an elongate barrier and sleeve type mounts, slidably receiving opposite ends of the barrier, including detent portions bearing against the barrier to inhibit such sliding movement.
It is another object of the present invention to provide a window guard having a transversely extending barrier, anchoring members adjustably mounted on opposite ends of the barrier for mounting the barrier outwardly of the outermost channel of a double channel window frame in which a window sash slides.
Still another object of the present invention is to provide the combination of a window having a double track frame mounting inner and outer window sashes and a window guard of the type described having a barrier mounted outwardly of the outer track and adjacent the sash which slides in the inner track, and including a transversely extending stop projecting inwardly into the path of an outer sash slidably movable on the outer track.
A still further object of the present invention is to provide a window guard of the type described including an anchoring member comprising a sleeve receiving a barrier rod and including a detent yieldingly bearing against the rod and engageable with a stop to prevent separation of the rod and the sleeve.
Other objects and advantages of the present invention will become apparent to those of ordinary skill in the art as the description thereof proceeds.
SUMMARY OF THE INVENTION
A window guard for a double hung window structure including a window frame slidably mounting at least one movable window sash, an elongate barrier, anchoring mechanism adjustably movable on opposite ends of the barrier for anchoring the guard to the window frame, and a transversely extending stop projecting into the path of the movable window sash.
The invention shall hereafter be more fully disclosed with reference to the accompanying drawings, in which:
FIG. 1 is a front elevational view illustrating apparatus constructed according to the present invention;
FIG. 2 is a sectional side view taken along the line 2--2 of FIG. 1;
FIG. 3 is an enlarged sectional plan view taken along the line 3--3 of FIG. 1;
FIG. 4 is an enlarged, fragmentary sectional side view, taken along the line 4--4 of FIG. 5;
FIG. 5 is a top plan view of the apparatus illustrated in FIG. 4;
FIG. 6 is a sectional side view, taken along the line 6--6 of FIG. 4, particularly illustrating the stop on the barrier interrupting the travel of the window sash;
FIG. 7 is a sectional side fragmentary view, taken along the line 7--7 of FIG. 8, illustrating a slightly modified construction; and
FIG. 8 is a top plan view of the apparatus illustrated in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A generally rectangular double hung window frame is generally designated 10 including vertical side frame members 12 spanned by upper and lower end frame members or headers 14 and 16. Each of the side frame members 12 includes inner, intermediate and outer, parallel vertical grooves or slots 16, 18 and 20 mounting generally vertical, blind stops or strips 22, 24 and 26 respectively. The blind stops 24 and 26 cooperate to define a vertical track or channel 30 extending between the upper and lower headers 14 and 16 respectively. Similarly, the blind stops 22 and 24 cooperate to define a vertical track or channel 32 extending between the upper and lower headers 14 and 16.
Slidably mounted in the inner and outer channels or tracks 30 and 32 are inner, lower and upper, outer sashes 34 and 36 respectively. Each of the sashes 34 and 36 include vertical side frame members 38 spanned by upper and lower frame members 40 mounting a glass pane 42, as usual. When the lower and upper sashes 34 and 36 are in their lowermost and uppermost closed positions, as illustrated in FIG. 1, the uppermost and lowermost end frame members 40 of the lower and upper sashes 34 and 36 are abutting as illustrated in FIG. 2. A conventional lock L is provided on the abutting window sash members to secure the sashes. Weather stripping, generally designated 44, is received in each of the channels or tracks 30 and 32 for inhibiting the passage of air between the inside and outside of the building wall W.
Apparatus constructed according to the present invention includes a window guard, generally designated 46, including upper and lower generally parallel bars or rods 48 spanned by linear vertical bars 50 and curvilinear bars 52 which form an aesthetic grid in the middle of the guard 46.
Each of the bars 48 is substantially rectangular in cross section but includes a twist or spiral section, generally designated 54, inwardly of each end thereof. The midsection 56 of the bar 48 has a height h which is substantially less than its breadth B and substantially less than the heighth H of the terminal ends 58. The twist section 54 disposes the end portions 58 of the bar at a 90° angle relative to the midsection 56 so that the height H of the end section 58 is substantially greater than the breadth b of the end section 58. The reduced breadth b enables the end section 58 to fit between the window sash 36 and a screen or storm sash 55. The twist or spiral sections 54 also increase the rigidity of the bar 54. The ends 58 includes a pair of upper and lower detent receiving slots 60 for a purpose to become immediately apparent.
Anchoring members, generally designated 62, are provided for anchoring the transversely extending bars 48 on the outermost blind stop 26. Each of the anchoring devices 62 includes a sleeve 64 receiving a terminal end 58 of a barrier bar 48. The sleeves 64 include ornamental, curvilinear upper and lower end portions 66 at one end thereof. The opposite end of the sleeve 64 terminates in mounting brackets 68 having generally vertical, linear mounts 70 which bear against the outermost blind stop 26. Tamperproof screws 71 are utilized to anchor the mounting brackets 68 to the outermost blind stop 26.
The sleeve 64, which is rectangular in cross section, includes upper and lower end walls 72 and 74 spanned by vertical side walls 76. The top wall 72 is cut along the lines 80, 81 and 82 (FIG. 5) and the resultant tab 78 is bent downwardly to form a detent received by the slot 60 along the upper side of the terminal bar end 58. The sleeve 64 is formed of spring steel and detent 78 will yieldingly bear against the bar sidewall 60a of the slot 60 to inhibit free sliding movement of the bar 58 while permitting restricted sliding movement thereof. The slot 60 includes an end wall 60b which will bear against the terminal end 78a of the detent 78 and prevent the escape of the sleeve 64 off the end of the terminal bar portion 58. The detent 78 will permit free sliding movement in the opposite direction. The cooperating detents 78 and slots 60 permit the anchoring sleeves 64 to be longitudinally adjusted along the slots 48 to accomodate windows of differing widths.
The window guards 46 are mounted in vertically spaced relation as illustrated in FIG. 1. The uppermost bar 48 of the lowermost window guard 46 will include a stop 48a on the bar midportion 56 which projects inwardly into the path of the uppermost sash 36 as illustrated in FIG. 6, to interrupt sliding movement thereof. If the lock L, which normally locks the upper and lower sashes 34, 36 together, is inadvertently unlocked and a burglar would attempt to move the uppermost sash 36 downwardly, the stop 48a will interrupt the downward movement of the window sash 36 beyond a predetermined distance as illustrated in FIG. 6. The sash window guards 46 permit the passage of air therethrough and yet provides an aesthetically pleasing barrier which permits viewing.
A storm sash or screen sash, generally designated 55, may suitably be mounted on the outer blind stop 26. If desired the upper window guard 46 could be eliminated and only the lower guard provided. The elimination of the upper window guard 46 would permit much easier ingress by a fireman who might have to break the glass to pass through the window. This arrangement would still provide protection in that the burglar could not enter through the lower sash 34. It is suggested that the glass 42, or at least the upper sash 36, be shatterproof. The guard 46 can also be used on a casement type window between the sash and screen.
ALTERNATE EMBODIMENT
A slightly modified construction is illustrated in FIGS. 7 & 8 and generally similar parts will be designated by generally similar numerals prefixed by the numeral 1. The bar 148 differs from the bar 48 in that the bar 148 includes a relief slot 188 in the terminal end thereof to define a pair of bifurcated legs 189 which permits the member 168 and the bar 148 to be dismantled. The bifurcated legs 189 each include a slot or notch 160 which is substantially shorter than the notch or slot 60, for receiving a spring detent or tab 178 formed in the anchors 162. The notch 160 receives the spring detent 178 and precludes the anchoring member 162 from being inadvertently removed so far off the end of the bar 148 that the structure would be unsafe. As illustrated, the mounting brackets 168 have a slightly different aesthetic design than the mounting brackets 68.
It is to be understood that the drawings and descriptive matter are in all cases to be interpreted as merely illustrative of the principles of the invention, rather than as limiting the same in any way, since it is contemplated that various changes may be made in various elements to achieve like results without departing from the spirit of the invention or the scope of the appended claims. | An anti-burglar guard for a double hung window construction including a generally rectangular frame having upstanding side frame members mounting vertically staggered slidable sashes. The window guard includes a transversely extending elongate barrier and anchoring members, adjustably mounted on the barrier, for mounting the barrier on the side frame members adjacent one of the window sashes. The barrier mounts a stop which projects into the path of the other window sash to limit sliding movement thereof. | 8 |
REFERENCE TO RELATED APPLICATIONS
The subject matter of this application is related to that of U.S. Pat. No. 4,401,044, entitled "System and Method for Manufacturing Seamed Articles", and U.S. patent application Ser. No. 345,756, entitled "Automated Seamed Joining Apparatus", filed Feb. 4, 1983, and U.S. patent application Ser. No. 515,126, entitled "Automated Assembly System For Seamed Articles", filed July 19, 1983.
BACKGROUND OF THE INVENTION
This invention relates to the assembly of seamed articles made from limp material, such as fabric. In particular, the invention relates to systems for automated, or computer-controlled, assembly of seamed articles from limp material.
Conventional assembly line manufacture of seamed articles constructed of limp fabric consists of a series of manually controlled assembly operations. Generally tactile presentation and control of the fabric-to-be-joined is made to the joining, or sewing, head under manual control. One drawback of this application technique is that the technique is labor intensive; that is, a large portion of the cost for manufacture is spent on labor. To reduce cost, automated or computer-controlled manufacturing techniques have been proposed in the prior art.
An automated approach to fabric presentation and control is disclosed in U.S. patent application Ser. No. 345,756. As there disclosed, pairs of belt assemblies are positioned on either side of a planar fabric locus. The respective belt assemblies are driven to selectively provide relative motion along a reference axis to layers of fabric lying in the fabric locus. A joining, or sewing, head is adapted for motion adjacent to the fabric locus along an axis perpendicular to the reference axis. The respective belts maintain control of the limp fabric in the region traversed by the sewing head, with the respective belts being selectively retracted, permitting passage therebetween of the sewing head as it advances along its axis of motion. With this approach, control of the limp fabric is permitted in the regions which are to be joined.
Systems for the manufacture of seamed articles from a strip of limp fabric disclosed in U.S. patent application Ser. No. 515,126 provide more precise "near field" control of limp fabric, that is fabric control in regions close to the sewing head. Those systems include a feeder for selectively feeding these strips of limp fabric in the direction of a first (Y) reference axis. Control of presentation may also be maintained in a second (X) axis perpendicular to and intersecting the Y axis.
In some forms, a folding apparatus controls the position of the fabric so that the strip of fabric is folded onto itself along a fold axis offset from the axis of feed (Y axis) so that there is a folded portion having an upper layer overlying a lower layer. A support is used to position the upper and lower layers of the folded portion in a substantially planar fabric locus.
In one form of those systems, the support includes a frame member, a support assembly coupled to the feeder, and a drive motor and an associated linkage for selectively positioning the frame member with respect to the support assembly in the direction of the X axis. A pair of lower belt assemblies is coupled to the frame member, where each lower belt assembly includes a plurality of continuous loop lower belts underlying the fabric locus. The lower belts are adapted on their outer, uppermost surface for frictional coupling with the lower layer of the folded portion. The lower belt assemblies are adjacently positioned along the X axis, with each assembly including an associated driver for selectively driving the lower belts so that the lower fabric layer coupled to those belts is positionable in the direction of the X axis.
A pair of upper belt assemblies is coupled to the frame member as well. The upper belt assemblies are adapted to be positioned to overlie the lower belt assemblies. Each of the upper belt assemblies includes a plurality of upper belts (which may be positioned opposite the respective lower belts). The upper belts have planar lowermost portions spaced apart from the uppermost of the lower belts. The upper belts are adapted on their outer, lowermost surface for frictional coupling with the upper layer of the folded portion. Each of the upper belt assemblies has an associated driver for selectively driving those upper belts so that the lower layer coupled to those belts is positionable in the direction of the X axis. The region between the lowermost portions of the upper belts and the uppermost portions of the lower belts defines the fabric locus, so that the fabric locus is substantially parallel to the plane formed by the intersecting X and Y axes.
In general, a computer-controller is used to selectively control the drivers for the respective belts so that the upper and lower layers may be substantially independently positioned in the direction of the X axis along the fabric locus. In alternative forms of those systems, the respective belt assemblies may be controllable in the Y axis direction as well, so that the upper and lower layers may be substantially independently positioned in the direction of both the X and Y axes along the fabric locus, thereby permitting control motion of the respective layers in those directions.
A fabric joiner, or sewing head, includes an upper assembly and a lower assembly. These upper and lower assemblies are adapted for tandem motion along the direction parallel to the Y axis between the upper belt assemblies and the lower belt assemblies. An associated driver provides control of the position of the upper and lower assemblies of the joiner along its axis of motion. The joiner is selectively operable to form seams in fabric in the fabric locus under the control of a computer-controller.
In one form of the systems of those systems, at least one pair of the pairs of the adjacent belt assemblies includes opposing pairs of closed loop belts and an associated controller adapted so that the pairs of the closed loop belts are selectively retractable in the X direction to permit passage of the joining head therebetween in the Y direction, for example, in the manner disclosed in U.S. patent application Ser. No. 345,756.
The joining head may include a needle assembly having a thread-carrying, elongated needle extending along a needle reference axis perpendicular to the fabric locus. In operation, the needle is driven through the fabric locus in a reciprocal motion along the needle reference axis. The needle assembly further includes an upper feed dog assembly which is responsive to an applied upper dog drive signal for selectively driving the uppermost layer of fabric in the region adjacent to the needle in the direction of an upper axis which is perpendicular to the needle reference axis.
A bobbin assembly is generally used in those systems and is adapted for interaction with the needle assembly to form the stitches of the seam. The bobbin assembly includes a lower feed dog assembly which is responsive to a lower dog drive signal for selectively driving the lowermost layer of fabric in the region adjacent to the needle in the direction of a lower axis which is perpendicular to the needle reference axis.
In one form of those systems, a controller generates a part assembly signal representative of the desired position of the junction of the layers of fabric relative to those layers. Registration sensors provide signals representative of the current position of the respective uppermost and lowermost fabric layers. A controller provides overall control for the belt assemblies as well as the feed dogs and needle and bobbin assembly rotational and feed dog control, in order to achieve coordinated motions of the respective assemblies. With this configuration, the respective belt assemblies provide far field, or global, position control for the upper and lower fabric layers. The feed dogs provide near field, or local, position control for the upper and lower layers of fabric in the regions near the needle of the joining head.
While the above-referenced systems do effectively provide approaches for the automated assembly of seamed articles, there are limitations in those operations particularly regarding the positioning, orienting and folding of limp fabric in preparation for joining of seams. Further, automated assembly systems require a feedback control system in order to accomplish these preparatory operations. In all such operations, it is important that accurate and repeated edge positioning of fabric be achieved in order to assure uniform quality of garment assembly. Moreover, these aspects are particularly important in view of desired high volume, and in view of the prior art requirement of specialized assemblies, requiring pattern- and size- dependent clamps or fixtures. Another factor for such automated assembly systems is that such systems must be cost effective compared with the existing approaches.
Accordingly, it is an object of the present invention to provide an improved system for automatic assembly of seamed articles.
Another object is to provide an improved automated assembly system for seamed articles including a relatively low cost optical feedback system controlling fabric location and orientation.
Yet another object is to provide an improved folding apparatus for folding fabric in automated seamed article assembly systems.
SUMMARY OF THE INVENTION
Briefly, the present invention is directed to a limp material handling system including a manipulating system for selectively manipulating one or more layers of limp material. The manipulating system includes a support assembly adapted to support the material on a reference surface. The manipulating system further includes a selectively operable fold assembly which includes a gripping apparatus for mechanically coupling to (or grapping or gripping) a curvilinear region of at least an uppermost layer of material on the support surface, and an apparatus for contour controlling and positioning for that gripped region of material, and for releasing that gripped region. In forms of the inventon adapted for folding limp material, the fold assembly further includes apparatus for selectively lifting and lowering a gripped region of material, so that a lifted region may be lowered down to the reference surface or the next uppermost layer of material overlying that reference surface. The gripping and releasing apparatus, the contour controlling and positioning apparatus and the lifting and lowering apparatus are all selectively operable under control of a control apparatus, which is generally controlled by a microcomputer in the preferred forms of the invention.
Generally, the fold assembly is operative to grip a curvilinear region of the material, then to control the curvature of that gripped curvilinear region so that the region has a selected contour, and to selectively translate and rotate that gripped region to a selected location overlying an associated curvilinear region of the reference surface, and then the material is released. To fold the material, a lifting operation for the gripped region is interspersed with these operations. Then, that translated and/or rotated and/or reconfigured curvilinear region is lowered to the underlying associated curvilinear region of the reference surface, or onto material overlying that associated curvilinear region on the reference surface.
Particularly, in article assembly systems in accordance with the invention, the system further includes a seam joining apparatus, such as a sewing machine, which is selectively positioned along a reference axis. The seam joining apparatus is adapted to selectively join adjacent regions of one or more layers of the limp material elements passing through that reference axis. The assembly system further includes a multiple parallel endless belt assembly, which is adapted to selectively transport and align the limp material in order to present that material to the seam joining apparatus at points on the first reference axis.
This belt assembly also provides selective orientation of the limp material elements to be joined. The respective belts of the belt assembly are selectively controllable to provide a desired tension in the limp material elements in regions of the limp material adjacent to and including the first reference axis, so that seam joining occur under controlled tension. Furthermore, the belts may be selectively driven in order to reposition upper and lower layers of a multilayer material at the sewing head in order to accomplish relative positioning of those layers, and further to provide capability to achieve easing and the generation of three dimensional seams.
All of these operations are provided under the control of an assembly controller which establishes the selected positioning, folding and joining of the limp material to assemble seamed articles.
In some forms of the invention, an optical sensing system provides optical feedback to the controller in order to sense the current position and various characteristics of the material which is being assembled into articles. The optical sensing system provides information representative of the edges of such materials as well, so that the folding apparatus may operate to accomplish the desired manipulations and/or folds by controlling the positioning of the edges of the material in such a manner to achieve the desired manipulation and/or folding.
In one form of the invention, a particularly cost effective optical sensing system is provided by incorporating a television camera for generating video signals using a common axis illumination system. This configuration provides video signals representative of an image along the camera's optical axis of the reference surface and any limp material on that surface within the field of view of the camera. The reference surface provides a relatively high contrast optical reflectivity with respect to material positioned on that surface.
With this configuration, the article assembly system may construct seamed articles, such as garments, in a manner providing accurate and repeatable edge positioning, thereby leading to highly uniform quality of garment assembly. Particularly, the folding apparatus is well adapted to attaching to the limp material, picking that edge up, reshaping that edge as desired, and moving it and placing it down elsewhere on the surface with substantially high accuracy. The reshaping of the edge permits matching to another edge of material already on the surface, so that the overlying edges may be then joined to form a desired seam, thereby permitting joining of dissimilarly-shaped edges.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects of this invention, the various features thereof, as well as the invention itself, may be more fully understood from the following description, when read together with the accompanying drawings in which:
FIG. 1 shows an isometric representation of the principal elements of an exemplary embodiment of the present invention;
FIG. 2 shows a partially cutaway view of a support table for the system of FIG. 1;
FIG. 3 shows schematically the upper endless belts of the system of FIG. 1;
FIGS. 4A and 4B illustrate the operation of the retractable belts of the system of FIG. 1;
FIG. 5 shows an isometric representation of an exemplary fabric folding system for use with the system of FIG. 1;
FIGS. 6A-6F illustrate the folding and sewing operations performed during the automated assembly of a sleeve by the system of FIG. 1;
FIG. 7 illustrates the television camera and on-axis light source for the system of FIG. 1; and
FIG. 8 shows in block diagram form an exemplary configuration for generating the position signals for use with the system in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an isometric representation of principal elements of a preferred form of an assembly system 110 together with a set of intersecting reference coordinate axes X, Y and Z. The system 110 includes two support tables 112 and 114 and a seam joining assembly 116. The system 110 further includes an optical sensor system overlying table 112 and including a television camera 117 and a common-axis illumination system 118. In alternative embodiments, an additional optical sensor system may similarly overlie table 114, for use in loading or unloading and orienting limp material elements, for example.
Each of the support tables 112 and 114 includes a respective one of planar upper surfaces 112a and 114a. In alternative embodiments, other or both of the surfaces 112a and 114a may differ from planar. For example, those surfaces may be cylindrical about an axis parallel to the Y axis.
A set of parallel endless belts (120 and 122) is affixed to each of tables 112 and 114. Each set of belts 120 and 122 is pivotable about a respective one of axes 120a and 122a each of which is parallel to the Y axis from a position substantially parallel to one of surfaces 112a and 114a (closed) to a position substantially perpendicular to one of those surfaces (open). In FIG. 1, belt set 120 is shown in a partially open position, and belt set 122 is shown in a closed position substantially parallel to the top surface 114a of table 114.
FIG. 2 shows a partially cutaway view of the support table 112. That support table 112 as shown includes a perforated retro-reflective surface which forms the surface 112a. In the present embodiment, the surface 112a is formed by retro-reflective material type for example as manufactured by 3M Corporation, where that retro-reflective material forming the surface 112a includes a rectangular array of holes, each hole having a diameter equal to 1/32 inches, with the array having a center-to-center spacing of 1/16 inches. In alternate embodiments, the array may be other than rectangular, for example, hexagonal or spiral or circular with holes having a sufficient diameter and the adjacent holes of the array having center-to-center spacing appropriate to permit sufficient air mass flow therethrough to provide a suitable vacuum for holding limp material down to the surface. By the way of example, the array of holes in surface 112a may be established using a commercial laser.
In the presently described embodiments, the upper surface 112a overlies an aluminum plate having an array of holes which substantially matches the array of holes in the surface 112a. That aluminum plate 130 overlies a composite beam honeycomb table top 132 which includes an array of honeycomb tubular structures extending in the direction of the Z axis. That honeycomb table top 132 is supported over a multiple plenum valve module which provides selectively operable rows of valves. In FIG. 2, there are eight rows of valves shown, with six of those rows in the open position and two of those rows in the closed position. The valve module 134 is coupled to a vacuum blower 136 which in turn is driven by a motor 138. With this configuration, a vacuum is selectively provided to various regions at surface 112a. The vacuum is particularly useful in holding various layers of material in a desired position on surface 112a. The positionin may be accomplished by a material folding or by a material manipulator, for example. The surface 112a also has retro-reflective optical properties so that with top lighting, reflective light is directed in the Z direction to provide a high contrast background against any cloth object placed on surface 112a. The latter feature is particularly useful in systems having optical sensors which can identify the location and orientation of material on surface 112a.
The sewing assembly 116 includes a sewing machine 140 adapted for linear motion along the Y axis. The sewing machine is also pivotable about its needle axis as driven by control 124 by way of motor 142 and gear assembly 144. The sewing assembly 116 further includes an interlocking belt assembly including a first set of parallel endless belts 150 and a second set of parallel endless belts 152. The belts of sets 150 and 152 are adapted so that their lower surface may frictionally drive material between those lower surfaces and an underlying support surface 160 which is generally in continuous with surfaces 112a and 114a, under the control of the controller 124.
FIG. 3 shows the belt assemblies 120 150, 152, and 122, in schematic form, together with the sewing machine 140, wherein the belt sets 150 and 152 include alternating sets of three roller endless belts and two point continuous belts. In operation, the controller 124 controls the belts adjacent to the sewing head of sewing machine 140 to be retracted from the locus of the needle while that needle is in the region between the belts. Otherwise, the belts of the opposed sets 150 and 152 are adjacent to each other. The belts may be driven by controller 124 in a manner providing controlled fabric tension for fabric between the lower surface of the belts of sets 150 and 152 and the upper surface 158. In various embodiments of the invention, the surface 158 may also include multiple endless belt assemblies underlying respective belts of sets 150 and 152. The latter belt sets are also controlled by the controller 124 in order to achieve substantially independent control of upper and lower layers of fabric positioned between the sets of belts 150 and 152 and those sets underlying sets 150 and 152.
By way of example, the belts may be 0.03 to 0.04 inches thick, 3/8 inch wide neoprene toothed timing belts with polyester fiber reinforcement supported by toothed roller assemblies. A layer of polyurethane foam is attached to the outer belt surfaces with adhesive. With this configuration, the foam provide substantial frictional contact with material adjacent to the belts so that as the belt moves, it positions the fabric adjacent thereto in the corresponding manner. For t:e upper belts the layer is 3/8 inches thick and for the lower belts the layer is 1/4 inches thick. The thicker layer provides increased adapability for materials characterized by varying thicknesses,
FIG. 4A shows two interlocking belts 150a and 152a of the sets 150 and 152, in a first state, where the sewing machine head 140a is positioned other than between these two belts. FIG. 4B shows those same interlocking belts in a second state when the sewing head 140a is positioned between those two belts 150a and 152a. As shown in FIGS. 4a and 4b, each of belts 150a and 152a is positioned about three rollers, one of which is fixed (the rightmost roller shown in FIGS. 4a and 4b for belt 150a, and the leftmost roller shown in FIGS. 4a and 4b for belt 152a) and the other two of which for each of belts 150a and 152a are controllably positioned. With the present embodiment, as limp fabric to be sewn is adjustably positioned between the belts of sets of 150 and 152 and the surface 160, the sewing machine 140 may be selectively controlled to traverse the gaps established by the retracting belts along axis parallel to the Y axis of machine 140 so that selective stitching may be accomplished on that fabric, under the control of controller 124.
The system 110 further includes a material manipulation system for fabric on the support table 112. That manipulation system includes the controller 124, and a folding assembly 160. The folding assembly 160 includes a controllable arm portion 162 which is selectively movable in the Z direction and selectively rotatable about the axis 170. The folding assembly 160 includes a hinged, linearly segmented assembly 174. That assembly includes three elongated segments 180, 182, and 184. Each of the segments 182 and 184 is selectively rotatable with respect to segment 180 about one of axes 190 and 192, so that the orientation of those segments 182 and 184 are selectively controlled with respect to the angular orientation of segment 180, all under the control of controller 124. The segment 180 is rotatable about the axis 186 under the control of controller 124. Each of segments 180, 182 and 184 includes a plurality of gripping elements distributed along the principle axis of that segment.
The gripping elements are denoted in FIG. 1 by reference designation 180a, 182a and 184a. Each of the gripping elements is adapted for selectively gripping regions of any fabric underlying those elements. The arm portion 162 is selectively controllable in the Z direction. As a result, when the gripping elements are affixed to a portion of the material, that portion may be selectively lifted and then lowered (in the Z direction) with respect to the surface 112a. In the present embodiment, the elements 180a, 182a and 184a are also each selectively movable in a direction parallel to the X-Y plane in the direction perpendicular to the principle axes of the respective ones of segments 180, 182 and 184. The gripping elements 180a, 182a and 184a are also selectively rotatable about an axis 186.
With this configuration, the folding assembly 160 may be used as a material manipulator for material on surface 112a, whereby selective curvilinear portions of that material may be sequentially grabbed by the gripping elements, and then translated and/or rotated and/or reshaped, and then released. The folding assembly 160 may also be used as a material folder by selectively performing the operations described for the manipulator, interspersed with lifting and lowering operations, particularly as described in configuration FIGS. 6A-6F.
In one form of the invention, each of the gripping elements may comprise a substantially tubular member coupling a vacuum thereto, which may be selectively applied. Alternatively, each of the gripping elements may include a grabber which comprises an elongated member extending along an axis perpendicular to the Z axis having a barb extending from the tip closest to the surface 112a. In the latter embodiment, the elongated member, or barbed needles, may be selectively reciprocated in the Z direction under the control of controller 124.
FIG. 5 shows an alternative embodiment 160' for the assembly 160 of FIG. 1. In that FIG. 5, corresponding elements are identified with identical reference designations. In FIG. 5, assembly 160 includes an elongated carrier assembly 210 having a curvilinear central axis 212 extending along its length. Axis 212 is substantially parallel to surface 112a. In other embodiments, for example, where surface 112a is not planar, the axis 212 may not be parallel to surface 112a. In the present embodiment, the carrier assembly 210 includes a hinged housing (including sections 214, 216 and 217) and a flexible member 218 which is coaxial with axis 212. One end of flexible member 218 is fixed to housing segment 214 at point 220 and the other end is slidably coupled to housing segment 218 at point 222. Forcers 230 and 232 are adapted to applying transverse forces to member 218 at points between the end points to control the curvature of axis 212. As the forcers 230 and 232 control the orientation of the axis 212, each of the gripping elements may be selectively displaced to provide the desired orientation of the gripping elements. This embodiment in effect provides a cubic spline. In other embodiments, differing numbers of forcers may be used. In the assembly 160, flexible cubic (or higher order) splines may be used to position the gripping elements in any or all of segments 180, 182 and 184.
With either configuration 160 or 160', the gripping elements may be selectively driven to form a desired curvilinear contour over a portion of material on the table 112a. The gripping elements 180a, 182a and 184a may be selectively lowered to the material on the table 112a so that those gripping elements may be activated to couple to (or "grab") the material at a corresponding curvilinear region of at least an uppermost layer of the fabric on the surface 112a. To partially accomplish folding, the assembly 160 (or 160') may then be raised in the Z direction in a manner lifting that uppermost layer of the material.
The gripping elements may then be translated and/or rotated, and repositioned (to modify the curvature of axis 212) so that the grabbed region of the uppermost layer of material is repositioned to a selective location overlying a predetermined location over the surface 112a. The assembly 160 (or 160') may then be lowered so that the lifted material is adjacent to the surface 112a or overlying the material on surface on 112a. All of this operation is under the control of controller 124. The vacuum at surface 112a holds the material in position when that material is adapted to surface 112a.
By selectively performing this operation over desired curvilinear regions of the material, a desired folding operation of the material may be attained. FIGS. 6A-6F show an exemplary folding sequence for assembling a sleeve. In that figure, a multilayer fabric assembly is first sewn (with easing) along the dotted line designated 240 in FIG. 6A. That assembly includes an in-sleeve portion 242 and an out-sleeve portion 244. Initially, the gripping elements 180a, 182a and 184a may be positioned along the heavy lined portion of in-sleeve 242 denoted X in FIG. 6A. That contour may be then picked up and translated, reshaped and lowered (and held with vacuum at the surface 112) so that the contour X is reshaped and positioned at the 1ocation shown in FIG. 6B. With this configuration, the in-sleeve portion 242 has been folded about the axis A--A. The elements 180a, 182a and 184a may then release the material and the gripping elements may be rearranged to match the contour denoted Y in FIG. 6B. That portion of the material may then be picked up by the gripping elements and the contour reshaped so that it is then repositioned and shaped as shown in FIG. 6C, with contour X overlapping contour Y. As a result, the material assembly is then folded along line B--B. Then, contour Y is released and the elements 180a, 182a and 184a are controlled to grip the contour Z on portion 244 shown in FIG. 6C. That contour is then lifted and folded about line C--C as shown in FIG. 6D. Then contour Z is released and the gripping elements are configured to grip contour W shown in FIG. 6D. That gripped contour is then folded about line D--D, as shown in FIG. 6E. The sleeve assembly is then presented to sewing head 140a.
By performing a tacking operation, the sewing head 140a as shown in FIG. 6F, the sleeve may be partially assembled. The material may then be translated back out to the surface 112a, and the contour T of the out-sleeve 244 may be lifted by the assembly 160 (or 160') including elements 180a, 182a and 184a, and transferred and reconfigured to unfold about line C--C and match the contours X and Y as shown in FIG. 6F. The out-sleeve is then released from elements 180a, 182a and 184a, and the folded assembly is then transferred by way of belts 120 and 150 to the sewing head 140a, where the elbow seam 240 is then joined. Thus, with this configuration, the sleeve shown in FIG. 6F is assembled automatically under the control of controller 124. In all of these operations, the vacuum at surface 112a serves to hold material adjacent to that surface in place.
FIGS. 7 and 8 show the components of the optical sensor system of the present embodiment. FIG. 7 includes an optical sensor 117, and an illumination system 118. In the present embodiment, the sensor 117 is in the form of a conventional television camera, although other image signal generating devices may be used. The television camera 117 is supported so that its optical axis 117a is substantially normal to the surface 112a of the table 112. The illumination system 118 includes a light source 260 and an associated beam splitter 262. The beam splitter is positioned on the axis 117a between the camera 117 and surface 112a. That beam splitter 262, for example a mirror type beam splitter, is adapted to receive incident light from the light source 260 along path 260a, reflect a portion of that light along optical axis 117a to the surface 112a, and then to pass a portion of light reflected from surface 112a (or material positioned on that surface) back along the axis 117a to the television camera 117.
With this illumination arrangement, common axis illumination is achieved for the system for use with the retro-reflector configuration on surface 112a. The surface 112a may alternatively be formed by a translucent material which is backlit, or by a fluorescent surface (with appropriate filters for camera 117), although the retro-reflective common axis illumination approach is the preferred form for the present embodiment.
In operation, the camera 117 provides video signals representative of the image along the optical axis 117a of the surface 112 and any material thereon. The retro-reflective surface 112a in effect provide a high contrast background with respect to any material on surface 112.
At the controller 124, these video signals are processed to provide the position signals for use with the automatic seam joining and folding control portions of controller 124. FIG. 8 shows a block diagram of a portion of controller 124 which performs this function, in conjunction with the surface 112a, camera 117, and illumination source 118 and a video monitor 266. In the present embodiment, the controller 124 includes a type LSI-11/23 microcomputer, manufactured by Digital Equipment Corporation, Maynard, Mass. FIG. 8 also shows the interface between the camera and illumination system and the LSI-11/23 computer.
In operation, the functional block of controller 124 in FIG. 8 performs edge detection of the material against the background provided by surface 112a. The edge detection is performed by differentiating, or thresholding, the video signal generated by the camera 117 as the camera scanning beam sweeps across the image, marking the times within the sweep at which there is a predetermined change in video signal intensity. These various "edge" times for each scan line are provided to the computer upon request. By way of example, where the camera 117 is an RCA type TC1005/C49 camera, the image of the table may be scanned in two seconds, and the edge information provided to the microcomputer, together with some data checks and filtering on the raw data. Also within this time frame, the microcomputer computes the area of a material element in the field of view, the center of that area, and the angle the principal axis of that material with respect to the a reference axis on surface 112a. Appendices A and B show an exemplary technique for performing these data processing operations.
With this configuration, the television camera 117 provides an output signal from its video amplifier circuitry and uses a separately generated vertical sweep signal generated by a digital-to-analog converter controlled by the microcomputer in controller 124. With this arrangement, the D/A controlled vertical sweep provides capability to increase a number of scan lines and also to correct for non-linearity in a relatively inexpensive camera yoke. The timing and control portion of the controller 124 converts the event detectors put into a series of digital words that contain a time of the.event and the scan line number in which the event occurred. With this type system, a relatively high degree of edge resolution can be achieved without requiring the conventional type pixel-image processing approach, and associated substantial computation cost and time. In alternative embodiments of the invention, the overall seamed article assemblies system may be configured with conventional type optical sensing system, although at relatively high cost compared with the particularly cost effective system shown in FIGS. 7 and 8.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all change which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
APPENDIX A
Workpiece Recognition
A. Sensor Information
The camera scans the workpiece with respect to X-Y coordinates with the workpiece lying between X-coordinates O and X N with upper and lower limits X L and X H , respectively. Scan lines run parallel to Y-axis, separated by Δx. Scan information consists of y-values for background-fabric transitions in the y-dimension, where y 1 is the left edge transition and y 2 is the right edge transition in a scan line. The distance between left edge and right edge transitions for the i th scan line, Δy i , is equal to y 2i -y 1i . The differential area for the i th scan line, dA i equals Δx i Δy i , or (y 2i -y 1i ) dx, or dydx.
B. Computation ##EQU1##
C. Principal Axis with Respect to Centroid Coordinate Frame
The next step is to convert the moments from the measurement into centroid frame, which is parallel to the original frame, but offset by the coordinates of the computed centroid. The converted moments are: ##EQU2## where θ' corresponds to the angular offset of the workpiece centroid with respect to the principal axes.
D. Algorithm in BASIC
Below is shown all the BASIC language statements that are necessary to implement the "moment calculations". Only eight multiplications and nine additions or subtractions are required in the high-frequency loop. YL and YR represent the values for the left and right profile, respectively, of the workpiece for each scan line.
______________________________________100 FOR X = 0 to XMAX STEP DX110200 READ YL, YR210 DY = YR - YL220 YRSQ = YR * YR230 YLSQ = YL * YL240 DYSQ = YRSQ - YLSQ250 YRCUB = YRSQ * YR260 YLCUB = YLSQ * YL270300 SUM1 = SUM1 + DY310 SUM2 = SUM2 + X * DY320 SUM3 = SUM3 + DYSQ330 SUM4 = SUM4 + YRCUB - YLCUB340 SUM5 = SUM5 + X * X * DY350 SUM6 = SUM6 + X * DYSQ360370 NEXT X380390400 A = DX * SUM1410 XC = DX * SUM2/A420 YC = DX * SUM3/(2 * A)430440 IXX = DX * SUM4/3450 IYY = DX * SUM5460 IXY = DX * SUM6/2470480 IXX = IXX - YC * YC * A490 IYY = IYY - XC * XC * A500 IXY = IXY - XC * YC * A510 Theta = 0.5 * ATAN((-2*IXY)/(IXX - IYY))______________________________________
Appendix B
Sleeve Data Base
The following information forms the "data base" for the machine, before each sewing or folding operation, for each sleeve size and style. (Only the right or left sleeve need be defined):
1. Nominal visual Area of workpiece (A)
2. Reasonable Tolerance for computed area (±εA)
3. Centroid correction as function of area variation ( ∂x c /∂εA, ∂y c /∂εA)
4. With respect to a "sleeve" coordinate system (i.e., origin at centroid, x-axis along longitudinal principal axis):
A. Checkpoints (e.g. to identify left- vs. right-hand piece, verify measurement
expected coordinates of intercept of centroid axes (±x c ,y c ) and workpiece
reasonable tolerance for any detected edge (±εx, ±εy)
B. Seam "trajectory"
coordinates of first stitch (e.g. off leading edge)
number of individual stitches
individual stitch segments
Δx, Δy from previous stitch
maximum sewing machine speed over segment
easing rate over segment (standard material)
gap stretching rate over segment (standard material)
feeddogs up-down flag
presser foot up-down flag
C. Folding "trajectory"
The transformation from "plotting" to "centroid" coordinates involves a (x c ,y c ) offset, followed by a rotation by angle O: ##EQU3## The transformation relationship for the stitch segments (s i -s j ) is slightly different: ##EQU4##
To provide measurement and a First Reasonableness Test where both the workpiece and table coordinate frame visible within the camera field-of-view, the scan algorithm is as follows:
1. For each scan line i
Read y 1 , y 2 , . . . , y n (n varies with shape)
If (y 2 -y 1 )>ε or (y n -Y n-1 )>ε or if (y 3 -y 2 )<ε or (y n-1 -y n-2 )<ε then
increment a counter and use previous Δy i
For j=3 to n-2, step 2
Δy i =Δy i +(y j+1 -y j )
Accumulate y's for Area computation.
2. Compute Area as ##EQU5## 3. Compare A meas with A DB +εA DB If not in interval, repeat measurement and increment counter. If counter is beyond a threshold, alert operator.
For each scan line, partial sums can be accumulated for the centroid and principal angle: ##EQU6##
Using those partial sums, the centroid and principle angle can easily be calculated using the algorithm described in Appendix A, that is: ##EQU7##
To provide a Second Reasonableness Test and Right- vs. Left-Piece identification, even if the detected area, centroid, and principal angle seem reasonable, there may still be some ambiguity whether a "righthand" or "lefthand" piece was loaded and scanned.
Unless the piece is exactly symmetrical about its two principal axes, the four predicted x, y intercepts with the piece edges can be checked to (1) ascertain whether a right- or left-handed piece was loaded and (2) perform a final reasonableness test.
In the present form, only "mirror" loading about the piece longitudinal axis is allowed; i.e., only the y + and y - intercepts str used to determine whether a right- or left-handed piece was loaded. If the x + , x - are not confirmed, the piece is rejected (or centroid corrected). Thus, the piece can not be loaded backwards.
Also, if the predicted x c , y c intercepts are "close" and consistent with a slightly larger or smaller area, the centroid and principal angle is adjusted slightly to allow for miscut pieces or unpredictable manual folding variations.
An exemplary algorithm is as follows:
1. Determine if predictable intercepts y + , y - can be confirmed with actual camera data.
a. convert the x-components (in table coordinates) of y + and y - to a particular scan line number (i.e., i + , i - ).
b. convert the y-components (in table coordinates) of y + and y - to a particular camera y-displacement (i.e., Δy + , Δy - ).
c. Look at the raw camera data (or repeat the scan) for a y + value (i.e., tablepiece transition) along scan line i + and a y - value along scan line i - . Use a reasonable y for success criterion.
d. If concurrence results, proceed to Step 2. If not, swap y + and y - and repeat Steps 1a-1c (look for concurrence for mirror-image around x axis).
e. If concurrence results from swapping the y's, then change the sign of the y-component for all trajectory points (i.e., start-end of seam and y for each stitch).
f. If no concurrence again, then stop and inform operator.
2. Repeat Steps 1a-1c for x + and x - . If concurrence, preceed to Step 3; if not, stop and inform operator.
3. Correct the trajectory for the small differences between predicted and measured intercept values, using one of the following rules:
(a)
x.sub.c =x.sub.c +∂x.sub.c /∂εA
y.sub.c =y.sub.c +∂y.sub.c /∂εA
θ=θ+∂θ/∂εA
where ∂x c /∂εA, etc. are empirical values from the data base.
Then use the new x c , y c , and θ values to retransform the sewing/folding trajectory from centroid to table coordinates.
(b) Use the (x + (actual)-x + (predict)) value to correct all positive x-coordinates of trajectories (i.e., beginning and ending of seams and folds, but not Δx, Δy of stitches). This, if the detected x + point falls further from the centroid than the predicted x + point, "expand" the beginning or end of the trajectory further away from the centroid in the +x direction.
Repeat similarly for the -x, +y, and -y directions.
The last step prior to sewing is to transform the stitch trajectory from table into sewing module (control) coordinates.
It's preferred to define the x sewing axis as originating from the sewing gap so that the velocity of the workpiece may change as it crosses the gap, due to different main motor and stretching motor rates. In order to simplify sewing "navigation" equations,
(x TS , -y TS ) is subtracted from every non-stitch segment (i.e., non x, y) coordinate of the trajectory. This converts the centroid and seam start-end points into sewing coordinates.
The sewing translator is slewed to the y-coordinate of the start of the seam.
Simultaneously, the belts (and workpiece) are moved, continually keeping track of the x-coordinate of the centroid (or the first stitch) in sewing coordinates as it decreases toward zero (approaches the needle).
When (x c ) sewing reaches the value of
-(s 1 (x)- x c ) table
or (s 1 (x)sewing) reaches zero, (i.e., the start of the first stitch passes under the needle), and/or the fabric is detected under the needle, then sewing commences by issuing Δx, Δy commands to the belts and translator from the sewing trajectory.
The x-position of the centroid (or first stitch) is continually be updated, so that the piece can be brought back to the original position on the loading table (or taken to the proper position on the folding table) after sewing is completed.
When the centroid (or first stitch) passes across the sewing gap, its speed is goverened by the main motor and the stretching motor. | A limp material handling system includes a manipulating apparatus for selectively manipulating one or more layers of limp material on a support table. Folding is accomplished by lifting a curvilinear region of the material, reshaping that lifted region as desired, and lowering that lifted region to a curvilinear region on the support table. A seamed article assembly system incorporates the manipulating apparatus, a seam joining apparatus and a multiple parallel endless belt system for tactile presentation of the limp material to the seam joining apparatus. An optical sensing system provides information representative of the position of the limp material being handled. A programmable computer, or controller, coordinates and controls the operation of the manipulating apparatus, seam joining apparatus, belt assembly, and optical sensing system to provide automatic assembly of seamed articles. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to an apparatus to enable an operator to maintain visual contact with instruments or other visual sources of data after smoke and/or particulate from a fire or other sources has invaded the operator's environment. In particular, the present invention relates to a gas activated expandable hand-held enclosure that bridges the gap between the pilot and the windshield and/or instrument panel along the pilot's line of sight and provide a clear viewing path to the windshield and/or the instrument panel, thereby providing him with vital information for guiding the aircraft to a safe landing after smoke and/or particulate matter invades the cockpit area.
BACKGROUND OF THE INVENTION
[0002] Emergency vision devices for aiding pilots to see through vision-impairing smoke to maintain their visual access to critical information, such as that provided by an instrument panel and visual information available outside the cockpit to help pilots safely guide their aircrafts are disclosed in U.S. Pat. Nos. 4,832,287; 5,318,250; 5,202,798; 5,947,415 and 6,460,804, all issued to Bertil Werjefelt.
[0003] The present invention is an improvement over U.S. Pat. No. 6,460,804.
OBJECTS AND SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to provide an emergency vision device that is relatively compact and easily fits within a brief case.
[0005] It is another object of the present invention to provide an emergency vision device that is portable, lightweight and easily handled by the operator to assist him in various procedures and checklists required to operate an aircraft while under emergency smoke conditions.
[0006] It is still another object of the present invention to provide an emergency vision device that takes on a smaller shape for stowage when not in use and uses compressed gas to inflate it for deployment when the need arises.
[0007] In summary, the present invention provides an emergency vision device, comprising a collapsible tube made of airtight material and having an expanded form and a deflated stowage form; first and second clear members disposed at respective first and second ends of the tube to enable a user to see through the tube and observe a source of information at a distal end of the tube while smoke or other particulate matter is in the environment; and a portable gas cylinder having compressed clear gas and an outlet operably connected to the interior of the tube. The gas cylinder is operable to release the clear gas to fill the interior of the tube to expand the tube to the expanded form.
[0008] These and other objects of the invention will be apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of an emergency vision device, shown in its deployed inflated form.
[0010] FIG. 2 is a partial cross-sectional view taken along line 2 - 2 of FIG. 1 .
[0011] FIG. 3 is a perspective view of the device shown in FIG. 1 in a deflated stowage form.
[0012] FIG. 4 is a perspective view of the emergency vision device of FIG. 1 , showing straps for holding a flashlight.
[0013] FIG. 5 is another embodiment of an emergency vision device, shown in its deployed form.
[0014] FIG. 6 is a partial cross-sectional view across taken along line 6 - 6 of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0015] An emergency vision device R made in accordance with the present invention is disclosed in FIGS. 1 and 2 in a deployed inflated form. The device is in the form of a collapsible hand-held tube 2 made from an airtight fabric or other suitable materials. The tube 2 may be made from transparent or opaque material. The tube 2 is closed off at each end with respective transparent member 4 , such as clear plastic sheet, to allow the user to see through the tube. The tube 2 is sealed from the outside such that smoke or other particulate from a fire is prevented from invading the interior of the tube. In this manner, a clear view from one end to the opposite end of the tube is maintained for the user.
[0016] A gas cylinder 6 containing clear compressed gas is disposed within a hollow handle 8 . The gas cylinder. 6 is screwed to a standard valve assembly 7 , such as the one commonly used in a hand-held fire extinguisher. The gas cylinder 6 is used inflate the tube 2 from its deflated stowage form (see FIG. 3 ) to its deployed inflated form. The valve assembly 7 includes an activation lever 10 the operation of which causes the gas to flow into the interior of the tube 2 , causing the tube to expand to its deployed form. A string 12 is advantageously secured to one end of the lever 10 for convenience so that when the tube 2 is in the deflated form, as shown in FIG. 3 , the string 12 may be positioned in a visible location to the user for quick activation of the gas cylinder when the need arises to deploy the device R. An outlet 14 of the valve assembly 7 operably communicates with the interior of the tube 2 to fill and inflate the tube 2 when the gas from cylinder 6 is released.
[0017] The handle 8 is made in a standard way such that it can be opened to provide access to the cylinder 6 for replacement after each use.
[0018] A light source 16 with its own battery power and switch may be provided at one end of the tube 2 .
[0019] A closeable outlet 18 is provided to exhaust the gas from the interior of the tube 2 when deflating the device to its deflated and stowage form.
[0020] When not in use, the device R is in a deflated stowage form, as shown in FIG. 3 , and may be placed within a pouch (not shown). To deploy the device R, the lever 10 is operated in the conventional manner, activating the cylinder to release its content to the interior of the tube 2 via the inlet 14 , thereby inflating the tube 2 . The light 12 provides illumination on the object requiring visual visibility to the operator.
[0021] In lieu of the light 16 or in addition to it, a flashlight 20 may be attached to the outside of the tube 2 . Straps 22 with hook-and-loop fastener 24 are attached to the tube 2 for securing the flashlight. Other conventional ways to attach the flashlight to the tube may be used.
[0022] Although the tube 2 is shown with a circular cross-section, generally in the shape of a cylinder, it should be understood that any cross-sectional shape would be applicable as long as a clear visibility path is provided through the tube. In another embodiment, the tube 2 is surrounded and attached to a network of substantially smaller tubes 26 . The tubes 26 comprise end ring tubes 28 disposed at the respective front and rear end of the tube 2 . Intermediate ring tubes 30 are disposed intermediate the front and rear end of the tube 2 . Longitudinal tubes 32 connect the end ring tubes 28 and the intermediate ring tubes 30 into one communicating network of tubes. The network of tubes 26 provides a supporting framework when inflated to the tube 2 . Although a specific arrangement of small tubes 28 , 30 and 32 is disclosed, other arrangements may be used that would provide the same function of supporting the tube 2 in the deployed form. The ring tubes 28 and 30 and the longitudinal tubes 32 have a cross-sectional area substantially smaller than the cross-sectional area of the main tube 2 .
[0023] The outlet 14 of the valve assembly 7 communicates with the network of tubes 26 , preferably via one of the intermediate ring tubes 30 , as best shown in FIG. 6 . In this manner, the compressed gas fills up the network of tubes 26 relatively quickly, with the gas filling up the ring tube which functions as a header, connecting the longitudinal tubes 32 and the other ring tubes to facilitate the flow of the gas. Advantageously, the gas cylinder 6 only needs sufficient capacity to fill up the network of tubes 26 , which is much smaller than the volume required to fill up the tube 2 . Thus, the gas cylinder 6 for this embodiment can be made smaller and lighter than the one in the embodiment of FIG. 1 .
[0024] A filter 34 is disposed at one end of the tube to allow ambient air to fill the volume of the tube as it expands under the action of the network of tubes 26 as it fills up with the compressed gas from the cylinder 6 . The filter 34 is designed to filter the ambient air during an emergency smoke situation and provide clear air to fill the volume of the tube 2 . The filter 8 is preferably a HEPA filter.
[0025] A closable port or opening 36 is provided to allow the air inside the network of tubes 26 to be exhausted when the tube 2 is deflated for stowage. The air within the tube 2 is exhausted through the filter 34 .
[0026] The filter 8 may also be integrated into the wall of the tube 2 in various ways. For example, a portion or the entire tube wall may be made of filter material. The entire wall of the tube 2 may also be made of filter material.
[0027] In operation, the lever 10 is operated in the conventional manner to release the content of the cylinder into the network of tubes 26 , thereby inflating the tube 26 into the form shown in FIG. 5 . The action of the network of tubes 26 taking on the expanded form as shown in FIG. 5 forces the tube 2 to also expand, since the tube 2 is attached to the network of tubes 26 . The expanding tube 2 draws in ambient air through the filter 34 to equalize the pressure between the interior and the outside of the tube 2 . Clear air then fills up the interior of the tube 2 . The user then positions the device R between the user and the source of information, such an instrument panel, allowing him to read the information in spite of the smoke that may have invaded the space. After use, the tube 2 and the network of tubes 26 are deflated by compressing the tube 2 , forcing the air inside through the filter 34 , and allowing the gas within the network of tubes 26 to exhaust through the port 36 .
[0028] The tube 2 may be disposed outside the network of tubes 26 , as long as it is attached thereto. The tube 2 and the network of tubes 26 may be made from the same material and integrated into one unit.
[0029] The device R is advantageously lightweight, since it is completely supported by pressurized gas, without any metallic framework, such as a helical spring.
[0030] While this invention has been described as having preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims. | An emergency vision device, comprises a collapsible tube made of airtight material and having an expanded form and a deflated stowage form; first and second clear members disposed at respective first and second ends of the tube to enable a user to see through the tube and observe a source of information at a distal end of the tube while smoke or other particulate matter is in the environment; and a portable gas cylinder having compressed clear gas and an outlet operably connected to the interior of the tube. The gas cylinder is operable to release the clear gas to fill the interior of the tube to expand the tube to the expanded form. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Meat Animal Stunning Tools
2. Prior Art
The meat packing industry has long sought a quick, efficient humane and inexpensive means to stun animals for slaughter. With smaller animals electrical shock devices, hammers, sledges, and the like are often sufficient to stun the animals for slaughter. With larger animals, such as beef and horses, heavier blows to the skull are required. Various explosive charge devices has been employed with some satisfactory results, but they are expensive to operate, maintain and clean, require re-loading with expensive percussion cartridges usually after each stunning operation, and deposit hair, bone and filth in the skull of the animal, rendering the brain unfit for human consumption. All such devices require that a part of the skull be driven into the brain in front of a captive bolt (usually concave) dislodging a sufficient amount of skull material, which is deposited in the brain, to cause the animal to be rendered unconcious.
The problems associated with prior art devices have led to a search for a device which is less expensive to maintain and operate. As well, there was a need for an easily adjustable device, capable of varying the stunning force in dependence on the size of the animal involved.
SUMMARY OF THE INVENTION
The device of this invention solves the problem found in prior art. It is useful for all larger sizes of meat animals. Rather than use an explosive charge, it employs a penetrating needle, which, through a compressed air connection, deposits a controlled charge of air into the skull of the animal, stunning it quickly, efficiently, cleanly and humanely. Since the skull of such an animal is a closed chamber, except for the point of connection to the spinal cord, the sudden build of air immediately stuns the animal. It may also sever the spinal cord. By controlling the charge of air, utilizing variable air pressure and controlled sized port openings, the complete stunning of various size animals is assured. Also the device of this invention insures better bleeding of the stunned animal thereby improving the quality of the meat, and organs, including the brain, obtained therefrom. While it is preferable to use the device of this invention for large animals such as beef, cattle and horses, its range of use extends throughout all of the range of meat animals because it has adjustable, controllable features making it suitable for use in stunning all meat animals.
The basic tool of this invention is a hand held pistol shaped device. A source of compressed air connects to the device at an appropriate place, for example, to the base of the grip portion. The "muzzle" end houses or carries safety elements which when pressed against the skull of the animal, allows compression of the pilot valve through a linkage with the trigger which controls the air input. Compressed air when released by the trigger operating through a linkage causes the piston to advance, and hence a penetrating needle attached thereto. A hollow passageway extends from the rear of the penetrating needle to a nose portion and includes a passageway, through which the air may pass once the needle has penetrated into the skull of the animal in order to deposit a controlled charge of compressed air into the skull of the animal, stunning it so that slaughtering can proceed efficiently.
A plurality of valves are involved which are actuated by a linkage associated with the trigger and the contact safety elements to admit the charge of air to a valve which operates to cause the piston, and its connected penetrating needle, to move from its retracted position to a forward position into the skull of the animal. At the same time, other valves within the body of the housing carrying the elements of the device of this invention, operate to cause the piston and needle to retract automatically once the charge of air has been deposited in the skull of the animal. As an additional safety feature, the pressure contact, safety, and arming elements associated with the muzzle end of the device of this invention cock, in one embodiment, and remain in the operative position throughout the cycle and including the retracting cycle. This means that upon readying the tool for subsequent use, an additional safety feature is involved which requires that the forward elements be hand cocked in order to arm the device for the next stunning operation.
In an alternate embodiment a different valve is utilized, which eliminates one possible problem of having the penetrating needle hang up during the retraction step by providing a different valve which does not close until the needle is fully retracted.
Other objects and features of this invention will be understood from the description which follows below in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side view of the device of this invention;
FIG. 1A is a cross sectional view of the device of this invention, illustrating the starting position of the various elements in a preferred embodiment;
FIG. 1B is a view similar to FIG. 1A illustrating the extended position of the elements;
FIG. 2 is a rear elevation of the device of this invention;
FIG. 3 is a assembly drawing illustrating the parts which make up the main valve which operates to admit high pressure air behind the piston-needle assembly;
FIG. 4 is a side view of the assembled mainvalve;
FIG. 5 is a partial cross section of the front portion of an alternate form of the device of this invention;
FIG. 6 is a cross-sectional side view of the piston and needle assembly;
FIG. 7 is a partial cross-sectional side view of the penetrating end of the needle element;
FIG. 8 is a side elevation of one form of the retract valve element;
FIG. 9 is a cross-sectional view of the forward cushion element which serves to stop the piston-needle assembly's outer movement;
FIG. 10 and 10a constitute an exploded assembly drawing illustrating the parts of an alternate form of retract valve elements; and
FIG. 11 is a cross-sectional drawing of an adjustable control valve for adjusting the dwell time of the needle's penetration before the retract cycle starts.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1, 1A, and 1B, the preferred form of the device of this invention is illustrated in a manner which should permit ready understanding of the principle elements and their functioning in operation.
Starting at the front or muzzle end, it will be noted that there is an O ring latch spring 1 associated with an actionator head 2 located at what corresponds to the "muzzle" end of the pistol shaped device indicated generally in FIG. 1. A rotatably mounted steel ball 3 is positioned as illustrated and its operation and functioning will be described below. A retainer screw 4 interconnects the actionator head 2 and a retract valve housing 5 as illustrated. A O ring seal 6 positioned in the retract valve housing 5 seals the retract valve housing 5 with respect to a teflon lined steel tube portion 11 of the retract valve core body 9. A spring element 7 is positioned between the retract valve housing 5 and the retract valve seal 8, preferably made of teflon, which abuts the valve core body 9. A valve bumper 10 made of high impact plastic is interconnected to the valve core body 9. As illustrated the valve bumper 10 is positioned within a cylindrical housing 23 which constitutes the case or body 23 for the device of this invention.
There is another O ring seal 12, positioned as illustrated in FIG. 1A, which serves to seal the valve core body 9 when it advances toward the muzzle end of the device illustrated in FIG. 1. A leaf spring 13 attached to an actionator link bar 14 bears on the inner side of the actionator head 2 causing muzzle end of the bar 14 to bear on the steel ball 3 and hold it in place.
There is an actionator bar return spring 15 positioned above the trigger 16 in the pistol grip portion 23A of the stunner case 23.
The trigger 16 is carried within a trigger guard 18 and is pivotable about pin 16A. Actuation of the trigger 16 operates a coupling bar 17 pivotally attached to member 17A which is held into position illustrated in normal unactuated operation by means of trigger return spring 19. Immediately behind, looking to the right as illustrated in FIG. 1A of the coupling bar 17, there is a pilot control valve 20. Air under pressure, supplied by a conventional air compressor at from 80 psi to 160 psi, for example, through a connection to the pistol grip portion 23A, is present in the lower chamber area 23B and in drive valve chamber 25B. The pilot valve 20 has an intake port B which, when open as shown admits the air under pressure through tube 21 to the rear side of main drive valve 24.
Also housed within the stunner case 23 is a drive valve 24 as is more fully illustrated in FIGS. 3 and 4. The drive valve 24 comprised of a valve ring 25A, positioned as illustrated, which, along with a cylinder seal 26, in conjunction with O rings 27, 28, serve to assist in the sealing of the various parts which move relative to the fixed stunner case 23 and the drive valve 24. A ported ring guide 29 is incorporated and will be described in detail in connection with the operation of the device as set forth below.
In addition to the other ports previously described there is exhaust port A for the pilot valve 20, five valve exhaust ports C, a retract valve exhaust vent D, and exhaust vents E in the stunner case 23. Retract vent 26A in the rear of drive valve 24 releases the air under pressure behind piston-needle assembly 22 to atmosphere.
FIG. 2 is a rear view showing the pistol grip portion 23A, the rear end of the stunning casing 23, along with the associated drive valve case 24. In FIG. 3, the various elements making up the drive valve 24 are illustrated in a plurality of drawings showing how the various parts fit together, and the details thereof in general including a housing 24A, valve ring 25A, cylinder seal 26 and ported ring guide 29. This valve 24 is adapted from a device utilized for pneumatic driving of nails, and other than a few modifications the basic operation of the various components is well understood in the art. However, it will be appreciated that their utilization in a complete assembly as illustrated in FIG. 1 or in the alternate embodiment as illustrated in FIG. 5 is the subject matter of this invention and constitutes a use never contemplated for a valve of this type. The drive valve case 24A, through matching threads in the stunner case 23, is mounted in the rear end thereof. The manner in which the device operates to provide the controlled flow of air under pressure to operate the drive valve 24 hence to the rear of the piston, hollow needle assembly 22 will now be described.
Illustrated in FIG. 1A, i.e. the fully retracted position, the parts are in the positions as illustrated. In FIG. 1A, when the actionator head 2 has been depressed, moving the actionator bar 14 rearwardly, and the trigger 16 has been depressed moving the coupling bar 17 into position, so that the pilot valve 20 operates to close air under pressure off which holds drive valve 24 closed. This is the start of the operation of the device. When port B of pilot valve 20 is closed, elongated port A is partially opened allowing the air under pressure holding drive valve 24 closed to escape to atmosphere through the rear of pilot valve 20. The release of pressure from behind drive valve ring 25A unseats seal ring 26 as it moves to the right as shown in FIG. 1A. Since chamber 23C is at atmospheric pressure, the rearward movement of the drive valve 24 elements admits the air under pressure to the rear of the piston-needle assembly 22 driving it forward.
The acceleration of the piston-needle assembly 22 from at rest to a high speed, with its attendant mass, causes the tip 22C of the needle portion 22A to penetrate through the skull of the animal. When needle 22A enters the teflon liner portion 11 of retract valve core body 9 the entrapped air in chamber 23C in front of piston-needle 22 is bled out through vents D and E to atmosphere. A portion of the high pressure air, present in the hollow portion 22B of needle 22A, exits through orifice 22D in the tip portion 22C and enters the animals skull, instantaneously stunning the animal.
In FIG. 1B the parts are in the position which they would be in at the fully extended portion in which the penetrating needle 22A is fully extended and air is admitted through the hollow tube 22B into the skull of an animal being stunned by the device of this invention. At this point the automatic retract sequence operates. FIG. 1B illustrates the position of the parts at the initiation of the retract cycle.
SEQUENCE OF OPERATION
The actionator head 2 is placed on the animal, forcing it back which, through the linkages described above moves the pilot valve 20 into the firing position. Port B is crossed opening port A allowing air to escape from behind valve ring 25A through tube 21. When the trigger bar 16 is pulled back it forces coupling bar 17 up into the path of the actionator bar 14. As the valve ring 25A is forced back, ports C are closed on ported ring guide 29. Cylinder seal 26 is then pulled open allowing the air to enter a chamber 25 behind the piston 22 thus forcing the piston forward. Vents D and E as illlustrated in FIG. 1 permit air in front of the piston 22 to escape. The needle 22A penetrates the target, i.e. up to 21/2 inches, an adjustable amount, forcing air into the target through the hollow opening in needle and out through the opening in the muzzle ajacent end of the needle portion assembly 22A.
As the piston 22 contacts the valve bumper 10 vents D and E are closed. As the retract valve is opened the valve core body 9 forces the ball 3 outwardly releasing the actionator bar 14 from the catch in the actionator head 2. The ring latch 1 holds the head 2 in place, a spring 15 forces the actionator bar 14 forward releasing valve 20 and closing exhaust port A while at the same time opening port B allowing the drive valve 24 to close. Air is exhausted through port C to atmosphere. The retract valve 9 closes as the piston 22 is forced to stop in the position as illustrated in FIG. 1B thus stopping the air flow. The rubber bumper 22E serves to cushion the piston-needle's return and quiet the operation. Actionator 2 must be manually pulled forward prior to the next operating sequence.
Referring now to the device illustrated in FIG. 5 a modification of the device has been made which may avoid a problem which was encountered in some instances in connection with the device illustrated in FIG. 1 through FIG. 1B.
The specific problem addressed was that of the device hanging up during the retraction phase. That problem has been avoided by the valve having been incorporated in the muzzle portion of the device associated with the retraction mechanisim and porting so that the retract valve does not close until the needle is fully retracted. In the device as illustrated in FIGS. 1A and B there was a possibility of hanging up since the retraction phase and its associated valves might have a tendency to close prematurely, whereas the device as illustrated in FIG. 5 insures that the retract cycle operation will continue until the needle and piston assembly 22 has been forced back into its fully retracted position i.e. in the position illustrated in FIG. 1.
In the device illustrated in FIG. 5 an actionator head 31 is attached by means of a screw 32 to a retract valve housing 39. A body retainer member 37 sealed by means of an O ring seal 38 is connected to valve body 49. Bumpers 40 are positioned so that as the valve body 41 moves, sealed by O ring seal 43 assisted by return spring 42, vents openings 46 vent the return valve mechanisim 44 to atmosphere. There are bumpers 48. The retract valve housing 49 has an associated wear liner 50. Additional sealing members 45 assist in the operation of the device. As before there is a steel ball 34 and its retaining spring 35 associated with the actionator bar 36. Also there is a trigger 51 pivotally attached at 52 to a housing (not shown) which replaces the head 2 and its catch ring 1. A trigger guard 53 is also included for safety purposes.
In both of the forms of the device illustrated in FIGS. 1A and B and FIG. 5 it will be seen that the functioning of the retract mechanisim is substantially the same in both instances. The retract mechanisim is controlled by the retract valve and does not come into play until the end of the forward motion of the needle and piston which opens the ports permitting air under high pressure to enter the area immediately in advance of the piston. At this point in time the piston-needle assembly 12 is driven to the right as illustrated in the Figures so that it is forced to the right to return to the position illustrated in FIG. 1A.
Referring now to FIG. 6 the details of the piston-needle assembly 22 are illustrated. The piston itself is designed in such a manner that the needle may be a part of or may be a seperate device attached firmly to the piston. As illustrated in FIG. 6 the bumper member 22E is not present, how ever the piston itself with its attached needle 22A is present. It will be noted that there is a hollow opening 22B extending throughout the length of the piston-needle assembly 22 so that a portion of the air under pressure behind the piston from the chamber 25 is passed through the hollow needle portion 22B and accordingly is passed out through the openings 22D formed in the outerend so that, upon penetration of the point 22C, a controlled amount of air enters in the skull of the animal being stunned. As illustrated in FIG. 7 there the needle point 22C is chamfered in such a manner that nothing can hang up in the openings or ports 22D, thus, in effect the instrument is selfcleaning.
Illustrated in FIG. 8 is one form of the retract valve which shows the portion 80 which fits into a recess 81 in the bumper element 10 illustrated in FIG. 9. Ports 82 are drilled through the device as illustrated in FIG. 8 and are in communication with the opening through which the needle portion 22A passes. A teflon liner 11 is positioned within the bore of the device illustrated in FIG. 8 so as to guide and to seal the passage of the needle there through.
It will be appreciated that other elements such as retaining rings and support rings and the like may be required in order to physically position the device as illustrated in FIGS. 8&9 within the related portion of housing 23.
The device illustrated in FIG. 10 are the elements of the alternate form of retract valve illustrated in FIG. 5 in which a device 90 has outer shoulders which mate into a bumper ring 10 and have ports 92, 94, which are arranged in such a manner as to provide the opening of air passages therethrough in order to cause the operation of the retract valve, cup element 96 and a retaining element 98 are formed in such a manner so that, when inter-connected, the retract valve member illustrated in FIG. 5 can fulfill the purposes described therefor above.
A member 100 (got example, a block) having longitudinal drilled passages 102 and 103; and tranverse drilled passages 104 and 105 (sealed at 107) includes a thumb screw needle valve 106 threaded in one end of passage 103. The other end of passage 103 connects to main valve element 23A. Passage 102 is closed at one end and contains a ball valve element 108 and its return spring 109 which cooperate with valve seat 110 to block air passage from the main valve element 23A to the pilot valve 20, thus requiring the air to flow through passage 103 to passage 105 past adjustable needle valve 106. Thus the time the needle 22 remains in its extended position is adjustable by controlling the rate of flow from main valve element 23A, during the retract cycle, to the pilot valve 20 (and thence to atmosphere). During firing the air from pilot valve 20 may pass through passage 102, flow freely through valve seat 110, when flowing in that direction, to passages 104, 103 and thence to main valve element 23A.
It will be appreciated that specific forms of the device illustrated are sufficient to accomplish the results desired of solving the problem as set forth above which has been long existing the prior art. It will be understood however by men of ordinary skill in the art that modifications may be made in the specific form of apparatus disclosed which do not depart from the scope of the appended claims. | Disclosed is a stunning gun for meat animals including beef, buffalo, horses, veal, and the like comprises: a hand held pneumatic housing having a pistol grip and an actuating trigger; a forward animal contacting safety and release, arming portion; valve mechanism operated by the trigger's actuation; and a pneumatic airline supplying air under pressure to an extensible and retractable piston and needle assembly. Upon the admission of air under pressure behind the piston, a needle attached thereto is caused to move from its starting retracted rest position through an opening in the front or muzzle of the gun to penetrate an animal's skull, depositing a charge of air into the animal's skull, stunning it for slaughter. Air passages are arranged in connection with valves in the housing to cause the needle and piston to retract automatically to the starting position after the stunning operation is completed. | 0 |
PRIORITY CLAIM
[0001] This application claims priority from European patent application No. 05425676.3, filed Sep. 28, 2005, which is incorporated herein by reference.
TECHNICAL FIELD
[0002] An embodiment of the present invention relates to a process for manufacturing thick suspended structures of semiconductor material, in particular that can be used as inertial (or seismic) masses in micro-electromechanical devices such as integrated accelerometers, to which the following description will make reference without this, however, implying any loss in generality.
BACKGROUND
[0003] Processes for manufacturing thick suspended structures of semiconductor material are known to the art. Said processes initially envisage providing a layer of semiconductor material, and etching the layer of semiconductor material from the back, for example via an anisotropic wet chemical etch in TMAH (Tetra-Methyl Ammonium Hydroxide), so as to define a thick structure having a desired shape. Then, a covering layer is joined, for example via anodic bonding, to the layer of semiconductor material, underneath the structure previously defined. In particular, the covering layer has a recess in a position corresponding to said structure so that, following upon bonding between the two layers, the structure will be suspended above a cavity.
[0004] By way of example, FIG. 1 shows an accelerometer 1 of a piezoresistive type, comprising a thick suspended structure, in particular an inertial mass, made as described above.
[0005] In detail, the accelerometer 1 comprises a first layer 2 and a second layer 3 , bonded to one another, for example, via anodic bonding. The first layer 2 is made of semiconductor material, whilst the second layer 3 may be made of semiconductor material, or, alternatively, of glass or plastic.
[0006] The first layer 2 comprises a bulk region 4 and an inertial mass 5 , mechanically connected to the bulk region 4 via thin and deformable connection structures 6 . The inertial mass 5 is formed via a TMAH etching of the first layer 2 , made from the back; with the same etching the connection structures 6 are defined. The second layer 3 has a function of covering and mechanical support, and has a cavity 8 , in a position corresponding to the inertial mass 5 , so as to ensure freedom of movement for the inertial mass 5 . Piezoresistive detection elements 9 , for example constituted by regions doped by diffusion, are made in the connection structures 6 and connected in a bridge circuit.
[0007] During operation, an acceleration sensed by the accelerometer 1 causes a displacement of the inertial mass 5 . Consequently, the connection structures 6 , fixed to the inertial mass 5 , undergo deformation, and the resistivity of the piezoresistive detection elements 9 varies accordingly, unbalancing the bridge circuit. Said unbalancing is then detected by a suitable electronic circuit, which derives therefrom the desired acceleration measurement.
[0008] The described manufacturing process is rather complex, due to the presence of a wet etching to be carried out from the back of a layer of semiconductor material, and the need to provide a bonding with a covering layer. For this reason, micro-electromechanical devices comprising suspended structures formed through said process may be characterized by large overall dimensions and high costs.
SUMMARY
[0009] An embodiment of the present invention is a process for manufacturing thick suspended structures of semiconductor material that will enable the aforementioned disadvantages and problems to be overcome, and in particular that will have a reduced complexity and lower production costs.
[0010] Consequently, according to an embodiment of the present invention, a process for manufacturing a suspended structure of semiconductor material and a semiconductor structure comprising a suspended structure of semiconductor material are provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a better understanding of embodiments of the present invention, an embodiment is now described, purely by way of non-limiting example and with reference to the attached drawings.
[0012] FIG. 1 is a cross-sectional view of a micro-electromechanical structure of a known type.
[0013] FIG. 2 is a top plan view of a wafer of semiconductor material, in an initial step of a process for manufacturing a suspended structure, according to an embodiment of the present invention.
[0014] FIG. 3 is a cross-sectional view at an enlarged scale of details of the wafer of FIG. 2 , taken along the line III-III, according to an embodiment of the invention.
[0015] FIGS. 4-8 are cross-sectional views of the wafer of semiconductor material in subsequent steps of the manufacturing process according to an embodiment of the invention.
DETAILED DESCRIPTION
[0016] A process for manufacturing thick suspended structures of semiconductor material is now described. This process is based, in part, upon the process described in the European patent application 04 425 197.3, which is incorporated by reference.
[0017] FIG. 2 (which, like the subsequent figures, is not drawn to scale) shows a wafer 10 of semiconductor material, in particular monocrystalline silicon of an N type with (100) orientation of the crystallographic plane, which comprises a bulk region 11 .
[0018] In an initial step of the manufacturing process, a resist layer is deposited on a top surface 10 a of the wafer 10 , and it is defined so as to form a mask 12 (see also the cross-sectional view of FIG. 3 ). In detail, the mask 12 covers an approximately square area having sides I of, for example, 300 μm, with the sides parallel to the flat ( 110 ) of the wafer 10 . The mask 12 has a lattice structure 12 a (as may be seen from the enlarged detail of FIG. 2 ), defining a plurality of openings 13 of an approximately square shape. The openings 13 have sides t of approximately one micron, for example, 0.8 μm, and the distance d between opposite sides of adjacent openings 13 is also approximately one micron, for example, 0.8 μm.
[0019] Using the mask 12 ( FIG. 4 ), an anisotropic dry chemical etching of the wafer 10 is then carried out, to form deep trenches 14 in a position corresponding to the openings 13 . The depth of the deep trenches 14 is of the order of microns or of tens of microns (for example, 10 μm), and the deep trenches 14 are separated from one another by walls 15 of semiconductor material, which form together a single separation structure, having a section corresponding to the lattice structure 12 a.
[0020] Next, the mask 12 is removed, and an epitaxial growth is performed in a de-oxidizing atmosphere (typically, in an atmosphere with a high hydrogen concentration, preferably with trichlorosilane—SiHCl 3 ). Due to the epitaxial growth, a silicon closing layer 16 is formed (shown only in FIG. 5 ), which has a thickness of the order of microns (for example, 5 μm) and closes the deep trenches 14 at the top, entrapping the gas present therein. In particular, before the deep trenches 14 are closed at the top, a growth of silicon occurs therein, causing a reduction in the dimensions of said trenches. At the end of the epitaxial growth, the deep trenches 14 consequently have an oval cross section elongated in a direction perpendicular to the top surface 10 a.
[0021] A first thermal annealing treatment is then carried out in an atmosphere containing hydrogen or another inert gas (for example, nitrogen or argon) or else a combination of hydrogen and of another inert gas, at high temperature (around or higher than 1000° C.) for a first time interval, which lasts some minutes or some tens of minutes. Advantageously, the first thermal annealing treatment is carried out in a hydrogen atmosphere, at a temperature of 1200° C., and the first time interval is no longer than 30 minutes.
[0022] The high temperature promotes a migration of the silicon atoms of the walls 15 , which tend to move into a position of lower energy. In particular, the silicon atoms migrate through adjacent lattice positions, preserving the lattice structure of perfect crystal of the silicon. On account of said migration, the individual deep trenches 14 evolve towards conformations with lower surface energy, for example, from oval shapes to shapes of a spherical type, and then merge together to form a single buried cavity 17 , which is uniform and entirely contained and insulated within the wafer 10 ( FIG. 6 ). For example, the buried cavity 17 has a thickness of 2 μm and a square cross section with sides of 300 μm. The main internal walls, i.e., the top and bottom walls, of the buried cavity 17 are substantially parallel to one another and to the top surface 10 a of the wafer 10 . A surface region 18 of semiconductor material remains above the buried cavity 17 ; this surface region 18 is constituted in part by epitaxially grown silicon atoms and in part by migrated silicon atoms, and has a first thickness w 1 (in a direction orthogonal to the top surface 10 a ). For example, said surface region 18 can form a thin membrane, which is suspended in a flexible and deformable way above the buried cavity 17 .
[0023] Next, according to an embodiment of the present invention, a second thermal annealing treatment is carried out at high temperature (around or above 1000° C.) for a second time interval, having a duration of tens of minutes or of some hours. The conditions and operative parameters of the second thermal annealing treatment may coincide with those of the first thermal treatment; i.e., the second treatment may also made in hydrogen atmosphere and at a temperature of 1200° C.; in addition, the duration of the second time interval may be longer than 30 minutes.
[0024] Due to the second thermal annealing treatment, a further migration of the silicon atoms occurs: in particular, the silicon atoms of the bulk region 11 that “face” the inside of the buried cavity 17 migrate and are displaced, in the direction indicated by the arrows in FIG. 7 , towards a central portion 18 a of the surface region 18 . The resulting effect is that, whereas the ends of the buried cavity 17 remain substantially at the same depth with respect to the top surface 10 a of the wafer 10 , the centre of the buried cavity 17 progressively shifts towards the bulk region, moving away from the top surface 10 a . The buried cavity 17 consequently assumes a profile having, in a section orthogonal to the top face 10 a , a central stretch substantially parallel to the top face 10 a , and lateral stretches, joined to the central stretch, inclined with respect to the top face 10 a by an angle α of approximately 30°. The thickness of the central portion 18 a of the surface region 18 progressively increases, and the surface region 18 is “strengthened” until it forms a suspended structure 20 , of large thickness (i.e., of tens of microns, for instance, more than 10 μm, or, more than 50 μm), above the buried cavity 17 . In particular, the suspended structure 20 has a central portion 20 a and lateral portions 20 b , which surround the central portion 20 a . The central portion 20 a has a second thickness w 2 greater than the thickness of the lateral portions 20 b and than the first thickness w 1 of the surface region 18 . In addition, the suspended structure 20 has a bottom portion (adjacent to the buried cavity 17 ) having substantially the shape of a truncated pyramid turned upside down, and a top portion (adjacent to the top surface 10 a ) substantially corresponding to the surface region 18 . In particular, the side walls of the truncated pyramid are inclined by the angle α (of 30°) with respect to the top surface 10 a of the wafer 10 , and the height of the pyramid is equal to the difference w 2 -w 1 between the second thickness and the first thickness.
[0025] Proceeding further with the second thermal annealing treatment, the migration of the silicon atoms continues, and thus the dimensions of the inclined side walls and the second thickness w 2 of the suspended structure 20 increase, until the semiconductor structure of FIG. 8 is obtained, with the suspended structure 20 that has a bottom portion having substantially the shape of a pyramid turned upside down, and with the buried cavity 17 that has a V-shaped profile in a section transverse to the top face 10 a.
[0026] The second thickness w 2 , as likewise the shape (whether of a truncated pyramid or of a pyramid), of the suspended structure 20 is consequently a function of the duration of the second time interval, i.e., of the duration of the second thermal annealing treatment: for example, in one embodiment FIG. 7 corresponds to a duration of 60 minutes, whilst FIG. 8 corresponds to a duration of 6 hours. The value of the second time interval that leads to the formation of the suspended structure of FIG. 8 (i.e., to the end of the process of migration of the silicon atoms) depends, as may be inferred, upon the starting dimensions of the surface region 18 a , or, in a similar way, upon the sides I of the mask 12 . In addition, also the value of the second thickness w 2 at the end of the process of migration is linked to the dimensions of the surface region 18 a by simple trigonometric relations; for example, given a side I of 300 μm, said value is approximately equal to 90 μm.
[0027] Advantageously, given the substantial uniformity of conditions and of operating parameters of the first and second thermal annealing treatments, just one thermal annealing treatment may be carried out, so that the second treatment is a continuation of the first treatment, with a total duration of the single thermal annealing treatment equal to the sum of the first and second time intervals. In general, said total duration is more than 30 minutes, for example between 60 and 600 minutes. The formation of the surface region 18 is in this case only an initial step of a single migration process of the silicon atoms, which then leads to the formation of the suspended structure 20 .
[0028] The suspended structure 20 can advantageously be used within a micro-electromechanical structure, for example as inertial mass in an accelerometer. In this case, in a way not illustrated, the manufacturing process can proceed with the formation of thin and deformable connection structures between the suspended structure and the bulk region 11 of the wafer 10 , and with the formation of transduction elements, for example of a piezoresistive type, in said connection structures.
[0029] The described manufacturing process has numerous advantages.
[0030] In particular, it does not involve bonding steps, in so far as the suspended structure 20 and the underlying buried cavity are formed within a single monolithic body of semiconductor material, with advantages in terms of manufacturing costs and complexity.
[0031] The suspended structure 20 can thus advantageously be used in semiconductor structures, for example as inertial mass in accelerometers of a resistive or capacitive type, or else in cantilever accelerometers (in this lafter case, the suspended structure 20 is carried by a beam, in a position corresponding to one end thereof, and is suspended above the buried cavity). The resulting semiconductor structures have small overall dimensions, given the absence of bonding between different layers and of wet etches carried out from the back.
[0032] It is moreover possible to control the thickness (and the shape) of the resulting suspended structures in a precise way according to the duration of the thermal annealing treatment.
[0033] The manufacturing process described enables integration of integrated circuits of a CMOS type within the suspended structure 20 (in a per se known manner which is not illustrated).
[0034] Finally, modifications and variations may be made to what is described and illustrated herein, without thereby departing from the scope of the present invention.
[0035] For example, the step of epitaxial growth that leads to closing of the deep trenches 14 at the top ( FIG. 5 ) may not be envisaged. In fact, it is possible to obtain closing of the deep trenches 14 via the subsequent thermal annealing treatment and the consequent migration of the silicon atoms of the walls 15 .
[0036] In the described manufacturing process wafers of semiconductor material of a P type, instead of an N type, may be used in an altogether equivalent way. The orientation of the crystallographic plane is advantageously (100), in so far as experimental tests have sometimes shown difficulty in obtaining the same structures starting from wafers with (111) orientation. In particular, in the case of (111) orientation, the deep trenches 14 may not merge into a single buried cavity 17 during the thermal annealing treatment.
[0037] As an alternative to what has been described, via the mask 12 a hard mask can be obtained, for example made of oxide, which can then be used for the etching of the wafer 10 that leads to the formation of the deep trenches 14 .
[0038] The structure of the mask 12 (or, in an equivalent way of the aforesaid hard mask) and the shape of the walls 15 and of the deep trenches 14 can vary with respect to what is illustrated. For example, the mask 12 can have a structure that is complementary to the one illustrated in FIG. 2 and can comprise a plurality of portions of a polygonal shape (for example, square or hexagonal), arranged in a regular way to define an opening shaped like a (square or honeycomb) lattice. More in general, the walls 15 can be constituted by thin structures capable of enabling complete migration of the silicon atoms during the annealing step that leads to the formation of the buried cavity 17 . The masks 12 having a lattice structure are, however, the most advantageous for use in the manufacturing process described.
[0039] Finally, the area over which the mask 12 extends may have different shapes; for example, it may have a rectangular or a generically polygonal shape.
[0040] Moreover, the structure 10 , or a die or IC in which the structure is located, may compose part of an electronic system such as the air-bag-firing system of an automobile. | A process for manufacturing a suspended structure of semiconductor material envisages the steps of: providing a monolithic body of semiconductor material having a front face; forming a buried cavity within the monolithic body, extending at a distance from the front face and delimiting, with the front face, a surface region of the monolithic body, said surface region having a first thickness; carrying out a thickening thermal treatment such as to cause a migration of semiconductor material of the monolithic body towards the surface region and thus form a suspended structure above the buried cavity, the suspended structure having a second thickness greater than the first thickness. The thickening thermal treatment is an annealing treatment. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to novel zinc-based alloys as well as to the preparation and use thereof for producing thermal-sprayed coatings having improved corrosion resistance and adherence.
Thermal-spraying is a generic term designating a type of method according to which molten or semi-molten particles are propelled and allowed to strike a surface in a uniform manner to form a coating. Examples of such methods include flame-spraying and plasma-spraying as well as the so-called detonation gun process and jet coat process, which are all well known in the art.
Thermal spraying allows the production of coatings of a wide variety of materials provided that the coating material does not sublimate, decompose or excessively vaporize during thermal spraying. Metals, alloys, ceramics and polymers can thus be sprayed on almost any substrates such metals, plastics, wood, ceramics and composites. Thermal-sprayed coatings are used in many industrial applications to protect parts against degradation such as that caused by corrosion in a gas or liquid at ambient or elevated temperature, or wear by a gas, liquid or solid in an aggressive environment at ambient or elevated temperature. Thermal-sprayed coatings are also used for producing unique operating mechanical systems such as thermal barrier coatings or clearance control abradable seals for jet-engines, for reclamation of worn parts by spraying material where volume losses have occurred, for lubrication at high temperature and for producing various coatings having special purposes in the electronic, printing, drilling, atomic, aeronautic, mining and chemical industries.
Thermal-sprayed coatings can comprise only one layer of material or a plurality of layers of different materials. In the case of multi-layered coatings, the layer on the substrate is generally designated as a bond coat since most of the time its function is to serve as anchorage for other types of material; on the other hand, the last layer to be deposited is generally referred to as top coat. Bond coats have been developed to significantly increase performance and reliability of coating systems. On an historical basis, the development of bond coat materials have evolved from molybdenum in the early 1940's, to nickel-chromium alloys in the 1950's, to nickel-aluminum composites in the 1960's, to aluminium bronze in the 1970's, and to pre-alloyed nickel aluminium. All these bond coat materials have been primarily developed to increase the adherence of coatings and in some cases to provide at the same time a good oxidation resistance, and they are thus not suitable for protecting parts against aqueous corrosion in humid environment as found in outdoor structures. In this later case, coatings based on zinc, aluminium or their alloys have been particularly studied and have been extensively utilized. Thermal-sprayed aluminium coatings have been developed for U.S. Navy ships for corrosion control. These aluminum-based coatings present important drawbacks since they ave a residual porosity which is detrimental. Very effective organic sealer must be used to impede the penetration of water when such aluminium-based coatings are used. Moreover, these coatings cannot be used as a bond coat due to the presence of an organic sealer. Thermal-sprayed coatings have also been used for protection of outdoor structures in a wide range of environment. Zinc and zinc-aluminum alloys have been particularly successful in protecting large structures such as bridges in many countries. In this case, the coating is only used for aesthetic and corrosion control purposes. The adherence of these coatings is relatively low and they are thus unsuitable for use as bond coat.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to overcome the above drawbacks and to provide a coating material suitable for producing thermal-sprayed coatings having improved corrosion resistance and adherence, thus enabling such coatings to be used as a bond coat as well as a top coat.
According to one aspect of the invention, there is provided a novel zinc-based alloy comprising about 50 to 90 weight percent zinc and about 10 to 50 weight percent of at least one other metal selected from the group consisting of nickel, cobalt and iron.
It has been surprisingly found that thermal-sprayed coatings made of the above zinc-based alloy exhibit improved resistance to aqueous corrosion and are thus suitable for use as a top coat for protecting metallic parts against aqueous corrosion. These coatings are also particularly useful as a bond coat since they provide improved adherence and impede spalling of the top coat normally observed with existing bond coats in aqueous corrosion conditions. Corrosion potential measurements made on the zinc-based alloys of the invention confirmed the propensity and the capability of such alloys to form a galvanic cell providing an active cathodic protection to steel. This cathodic protection against corrosion is not affected by the presence of residual porosity so that no sealer is necessary to seal any residual porosity in order to effectively protect metallic parts against corrosion in humid environment.
The high vapor pressure of metallic zinc above its melting point normally leads to low density thermal-sprayed coatings with poor adherence and also to difficulties in injecting zinc powder due to sticking problems. It has surprisingly been found that the novel zinc-based alloys according to the invention can be thermal-sprayed without excessive zinc vaporization and without sticking problems. The unexpected decrease in vapor pressure of the alloys according to the invention as well as their higher melting point contribute to this different behavior during thermal-spraying and enable the production of thermal-sprayed coatings with superior adherence and high density. It has been discovered that a zinc-based alloy is absolutely necessary for observing such results as opposed to a powder constituted of composite particles made up from an agglomeration or a mechanical mixture of metallic elements. This result is particularly unforeseen since it would normally be expected that composite particles should melt and transform into alloyed particles when being subjected to thermal-spraying. This is not the case since, when the powder is not alloyed, there are two metallic elements with different melting points and the big difference in melting temperature causes the zinc to vaporize before the second element (i.e. nickel, cobalt or iron) has melted. Thus, since the melting temperature of the second element is well above the boiling temperature of zinc, excessive zinc vaporization occurs.
Accordingly, the present invention provides, in another aspect thereof, a coating material for forming corrosion-resistant thermal-sprayed coatings on metallic substrates, comprising a zinc-based alloy as defined above, in the form of particles having a size ranging from about 0.03 to about 0.15 mm.
The present invention also provides, in a further aspect thereof, a method of applying by thermal spraying a coating material onto a metallic substrate to form a corrosion-resistant coating, wherein use is made of a coating material as defined immediately above.
In order to be suitable for thermal spraying, the zinc-based alloys according to the invention must be transformed into powders with a particle size ranging from about 0.03 to about 0.15 mm. It has been observed in this respect that alloy particles having a size less than 0.03 mm are too readily vaporizable and thus vaporize before larger particles have undergone melting; the use of particles smaller than 0.03 mm should therefore be avoided. On the other hand, particles with a size greater than 0.15 mm require a very high energy transfer rate during thermal spraying for complete melting. This results in a disintegration of the particles into smaller particles which are then excessively vaporized. As alloy particles are seldom spherical, such a high energy transfer rate is very detrimental since causing the generation of larger temperature gradients within a same particle having a different geometrical configuration. This results again in excessive vaporization which is very detrimental to the thermal spraying process. In addition to presenting problems of obstructing the feeding means, particles with a size greater than 0.15 mm are also difficult to transport and require large amounts of powder carrier gases.
The novel zinc-based alloy of the invention is prepared, according to yet another aspect of the invention, by a process comprising the steps of heating together about 50 to 90 weight percent zinc and about 10 to 50 weight percent of at least one other metal selected from the group consisting of nickel, cobalt and iron, at a temperature above the melting point of the alloy, under an inert gas atmosphere at a pressure above vapor pressure of zinc at the said temperature, to cause melting of the zinc and solubilization of the other metal in the molten zinc while preventing zinc vaporization, and maintaining the zinc and the other metal at the said temperature over a period of time sufficient to ensure homogenization of the resulting alloy.
The zinc-based alloy thus obtained can thereafter be transformed into a powder of the desired particle size, by crushing or atomization depending upon the ductility of the alloy. For some ductile crystalline structures such as zinc-nickel alloys with more than 40% wt. % nickel, atomization is the only method by which powders can be prepared; in fact, it is not possible to use combination methods for the production of powders from these alloys.
DESCRIPTION OF PREFERRED EMBODIMENTS
In a preferred embodiment of the process for preparing the zinc-based alloys according to the invention, the zinc and the other metal, i.e. nickel, cobalt or iron, are heated at about 50°-250° C., preferably about 100°-150° C., above the melting point of the alloy for at least 30 minutes. The melting point of the zinc-based alloy can be determined from the phase diagrams of the metallic components.
The inert gas atmosphere in which the alloy is prepared is preferably maintained at a pressure of about 100 to 1000 KPa, so as to prevent zinc vaporization as well as zinc oxidation. Argon is preferably used as inert gas.
When preparing a zinc-nickel alloy, the zinc and nickel are preferably used in amounts of about 50 to 75 weight percent and about 25 to 50 weight percent, respectively. In the case of a zinc-cobalt alloy, the zinc and cobalt are preferably used in amounts of about 80 to 90 weight percent and about 10 to 20 weight percent, respectively. On the other hand, in the case of a zinc-iron alloy, the zinc and iron are preferably utilized in amounts of about 60 to 85 weight percent and about 15 to 40 weight percent, respectively.
After being allowed to cool to ambient temperature under the inert gas atmosphere, the zinc-based alloy can be transformed into a powder having a particle size of about 0.03 to 0.15 mm, preferably about 0.05 to 0.12 mm, so as to be suitable for thermal spraying.
The coating material according to the invention comprising zinc-based alloy particles is preferably applied onto a substrate by plasma-spraying. In this case, a plasma is first generated and the coating material is then admixed with the plasma to cause melting of the alloy particles and propelling of the molten alloy particles in a direction toward the substrate, the alloy particles having a residence time in the plasma which is controlled to cause melting of the alloy particles while preventing vaporization of zinc from the molten alloy particles. Thus, for example, where the plasma generated is a low-energy subsonic plasma, the residence time of the alloy particles in such a plasma should be about 0.5 ms. to prevent zinc vaporization while ensuring proper melting of the particles necessary for high adherence. Moreover, in order to optimize the efficiency of deposition, the distance which the molten alloy particles are allowed to travel prior to impact on the substrate should preferably be maintained between about 6 and 10 cm.
The thermal-sprayed coatings produced according to the invention generally have a thickness of about 0.075 to 0.5 mm, preferably about 0.15 to 0.25 mm, and can used as a bond coat as well as a top coat.
The following non-limiting examples further illustrate the invention.
pcl EXAMPLE 1
A zinc-nickel alloy comprising 70 wt. % zinc and 30 wt. % nickel and having a melting point of 875° C. was prepared by charging a mixture of 70 wt. % zinc granules and 30 wt. % nickel pellets in a crucible and placing the crucible thus charged into a controlled atmosphere chamber. The chamber was first air evacuated with a mechanical pump and then filled with argon at a slight positive pressure of 300 KPa. The crucible was thereafter heated at a temperature of 1050° C. under argon for 30 minutes, to cause melting of the zinc and solubilization of the nickel in the molten zinc. After cooling to ambient temperature under argon, the ingot alloy was crushed to produce a powder having a particle size ranging from 0.05 to 0.09 mm.
EXAMPLE 2
A zinc-nickel alloy comprising 50 wt. % zinc and 50 wt. % nickel and having a melting point of 1200° C. was prepared according to the procedure of Example 1, by heating a crucible charged with a mixture of 50 wt. % zinc granules and 50 wt. % nickel granules at a temperature of 1250° C. under argon for 45 minutes. The ingot alloy was atomized to produce a powder having a particle size ranging from 0.075 to 0.125 mm.
EXAMPLE 3
The powdered zinc-nickel alloy prepared in Example 1 was plasma-sprayed onto steel substrates to form a coating 0.150 mm thick according to the following parameters:
Subsonic mode--External Injection. Plasmadyne plasma torch.
______________________________________Plasmadyne eletrodes: Anode #145 Cathode #129 Gas Injector #130Current: 150 ATension: 52 VoltsPlasma-Arc Gas: Helium 78 l/min. Argon 20 l/min.Stand off distance: 7 cmPowder Carrier Gas: Argon 6 l/min.______________________________________
The adherence of the coatings obtained by the above method was determined according to the ASTM C-633 procedure and a bond strength in the range of 35 MPa was obtained.
EXAMPLE 4
The powdered zinc-nickel alloy prepared in Example 2 was plasma-sprayed onto steel substrates to form a coating 0.200 mm thick according to the following parameters:
Subsonic mode--Internal Injection. Bay-State plasma torch.
______________________________________Bay-State eletrodes: Anode #901356 Cathode #902352-1Current: 530 ATension: 35 VoltsPlasma-Arc Gas: Argon 64 l/min.Stand off distance: 7.6 cmPowder Carrier Gas: Helium 16 l/min.______________________________________
The adherence of the coatings obtained was determined according to the ASTM C-633 procedure and a bond strength in the range of 30 MPa was obtained.
EXAMPLE 5
An ingot alloy of 70 wt. % zinc and 30 wt. % nickel was prepared according to the procedure of Example 1. The ingot was crushed to produce a coarse powder having a particle size ranging from 0.09 to 0.15 mm. This powder is then plasma-sprayed onto steel substrates to form a coating 0.200 mm thick according to the following parameters:
Subsonic mode--Internal Injection. Bay-State plasma torch.
______________________________________Bay-State eletrodes: Anode #901356 Cathode #902352-1Current: 450 ATension: 33 VoltsPlasma-Arc Gas: Argon 64 l/min.Stand off distance: 7.6 cmPowder Carrier Gas: Helium 16 l/min.______________________________________
The adherence of the coatings made with coarse powder was measured by ASTM C-633 and a bond strength of 40 MPa was obtained.
EXAMPLE 6
Plasma-sprayed coatings consisting of a zinc-nickel alloy comprising 70 wt. % zinc and 30 wt. % nickel were prepared according to the procedure of Example 3. A top coat, 0.200 mm thick, of a wear resistant chromium oxide (Cr 2 O 3 ) was plasma-sprayed onto this zinc-nickel coating. Moreover, chromium oxide coating was plasma-sprayed directly onto steel substrates without a zinc-nickel bond coat. These two types of coating were tested for corrosion performance according to the B-117-85 ASTM procedure. After 1000 hours of corrosion exposure, the adherence of coatings was measured. Results indicated that the adherence of chromium oxide coatings without a 70-30 zinc-nickel bond coat was practically reduced to nothing (1 MPa). On the other hand, the initial adherence of chromium oxide coatings with an under layer of 70-30 wt. % zinc-nickel alloy was maintained.
EXAMPLE 7
Plasma-sprayed alumina coatings with and without a 70-30 wt. % zinc-nickel alloy were prepared according to procedure of Example 4. The adherence of these coatings was measured after 1000 hours of corrosion in a salt-spray test (ASTM B-117-85). It was observed that the adherence of alumina coatings without a zinc-nickel bond coat was reduced to a negligible value (spalling conditions) whereas the adherence of alumina coatings with a zinc-nickel underlayer was maintained.
EXAMPLE 8
A zinc-nickel alloy comprising 90 wt. % zinc and 10 wt. % nickel and having a melting point of 790° C. was melted in air. Powder was prepared from the alloy melt by atomization with nitrogen, thus obtaining particles having a size ranging from 0.04 to 0.09 mm. This powder was then plasma-sprayed onto steel substrates to form 0.25 mm thick coatings. These coatings were tested for 600 hours in a salt spray test according to the B-117-85 ASTM procedure. The adherence of the coatings was maintained to its original value (before exposure).
EXAMPLE 9
A zinc-cobalt alloy comprising 90 wt. % zinc and 10 wt. % cobalt and having a melting point of 800° C. was prepared according to the procedure of Example 1, by heating a crucible charged with a mixture of 90 wt. % zinc granules and 10 wt. % cobalt granules at 1200° C. under an argon atmosphere at a pressure of 900 KPa, for 30 minutes.
A corrosion potential measurement was carried out with a high impedance electrometer. The test was carried out in a 3% NaCl solution with a saturated calomel reference electrode and revealed a strong negative potential of -950 mV/ECS after stabilization. Such a potential confirms the propensity of the above zinc-cobalt alloy to form a galvanic cell providing an active cathodic protection to steel.
EXAMPLE 10
A zinc-iron alloy comprising 60 wt. % zinc and 40 wt. % iron and having a melting point of 1060° C. was prepared according to the procedure of Example 1, by heating a crucible charged with a mixture of 60 wt. % zinc granules and 40 wt. % iron granules at 1200° C. under an argon atmosphere at 900 KPa, for 30 minutes.
A corrosion potential measurement was carried out in the same conditions as in Example 9 and revealed a strong negative potential of -875 mV/ECS after stabilization. Such a potential confirms the propensity of the above zinc-iron alloy to form a galvanic cell providing an active cathodic protection to steel. | A zinc-based alloy comprising about 50 to 90 weight percent zinc and about 10 to 50 weight percent of at least one other metal selected from the group consisting of nickel, cobalt and iron. The zinc-based alloy according to the invention is particularly suitable for use as coating material for producing thermal-sprayed coatings having improved corrosion resistance and adherence. | 2 |
CROSS REFERENCE(S) TO RELATED APPLICATION(S)
[0001] This application is a continuation-in-part of pending application Ser. No. 10/029,575 filed Dec. 21, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to spun yarn comprising polyester staple fiber and cotton, more particularly such a yarn in which the polyester staple is a bicomponent that imparts desirable properties to the yarn.
[0004] 2. Discussion of Background Art
[0005] Polyester bicomponent fibers are known from U.S. Pat. Nos. 3,454,460 and 3,671,379, which disclose spun yarns made from bicomponent staple having certain ranges of crimp properties outside of which the yarns are said to be boardy, harsh, and aesthetically undesirable.
[0006] Spun yarns comprising bicomponent staple fibers are disclosed in Japanese Published Patent Applications JP62-085026, and JP2000-328382 and U.S. Pat. No. 5,874,372, but such fibers can have little recovery power and need to be mechanically crimped, which adds to their cost.
[0007] Polyester fibers having longitudinal grooves in their surfaces are described in U.S. Pat. Nos. 3,914,488, 4,634,625, 5,626,961, and 5,736,243, and Published International Patent Application WO01/66837, but such fibers can lack good stretch and recovery properties.
[0008] Spun yarns of polyester bicomponent staple fibers and cotton that have high stretch and uniformity characteristics are still needed.
SUMMARY OF THE INVENTION
[0009] The present invention provides a spun yarn having a total boil-off shrinkage of at least about 22% and comprising cotton and a bicomponent staple fiber comprising poly(ethylene terephthalate) and poly(trimethylene terephthalate) wherein the bicomponent fiber has, a crimp development value of at least about 35% and no higher than about 70%, a crimp index value at least 15% and no higher than about 45%, a length of at least about 1.3 cm and no higher than about 5.5 cm, a linear density of at least about 0.7 decitex per fiber, and no higher than about 3.0 decitex per fiber, and wherein the bicomponent fiber is present at a level of at least about 20 wt % and no higher than about 65 wt %, based on total weight of the spun yarn and wherein the cotton is present at a level of at least about 35 wt % and no higher than about 80 wt %, based on total weight of the spun yarn.
[0010] The invention also provides a process for making spun yarn from cotton and the bicomponent fiber of the invention, comprising the steps of:
[0011] a) providing the bicomponent staple fiber;
[0012] b) providing cotton;
[0013] c) combining at least the cotton and the bicomponent staple fiber so that: the bicomponent fiber is present at a level of from about 20 wt % to about 65 wt %, the cotton is present at a level of from about 35 wt %, to about 80 wt % based on total weight of the blended fibers;
[0014] d) carding the blended fibers to form a card sliver;
[0015] e) drawing the card sliver;
[0016] f) doubling and redrawing the card sliver up to about 3 times;
[0017] g) converting the drawn sliver to roving; and
[0018] h) ring-spinning the roving to form the spun yarn.
[0019] The invention further provides a fabric selected from the group consisting of knits and wovens and comprising such a spun yarn as made by the process of the invention.
BRIEF DESCRIPTION OF THE FIGURE
[0020] The FIGURE shows a schematic cross-section of a spinneret pack useful in making bicomponent polyester fiber tow.
DETAILED DESCRIPTION OF THE INVENTION
[0021] It has now been found that spun yarn comprising cotton and a bicomponent staple fiber which in turn comprises poly(ethylene terephthalate) and poly(trimethylene terephthalate) and has selected mechanical properties, has unexpectedly high stretch characteristics, cardability, and uniformity.
[0022] As used herein, ‘bicomponent fiber’ means a fiber in which two polymers are in a side-by-side or eccentric sheath-core relationship and includes both spontaneously crimped fibers and fibers with latent spontaneous crimp that has not yet been realized.
[0023] “Intimate blending” means the process of gravimetrically and thoroughly mixing dissimilar fibers in an opening room (for example with a weigh-pan hopper feeder) before feeding the mixture to the card or of mixing the fibers in a dual feed chute on the card, and is to be distinguished from draw-frame blending.
[0024] The spun yarn of the invention comprises cotton and a polyester bicomponent staple fiber comprising poly(ethylene terephthalate) (“2G-T”) and poly(trimethylene terephthalate) (“ 3 G-T”) and has a total boil-off shrinkage of at least about 22%. Such shrinkage corresponds to about 20% elongation when a 0.045 g/den (0.04 dN/tex) load is applied to the yarn after boil-off in the yarn. When the total boil-off shrinkage is less than about 22%, the stretch-and-recovery properties of the yarn can be inadequate. The bicomponent staple fiber has a crimp development (“CD”) value of at least about 35% and no higher than about 70% and has a crimp index (“CI”) value of at least 15%, preferably at least about 20%, when substantially free of interlacing, and no higher than about 45%, preferably no higher than about 42%, more preferably no higher than about 30%.
[0025] When the CD value is lower than about 35%, the spun yarn has too little total boil-off shrinkage to generate good recovery in fabrics made therefrom. When the CI value is low, mechanical crimping can be necessary for satisfactory carding and spinning. When the CI value is high, the bicomponent staple can have too much crimp to be readily cardable, and the uniformity of the spun yarn can be inadequate.
[0026] The bicomponent staple fiber has a length of about at least about 1.3 cm and no higher than about 5.5 cm. When the bicomponent fiber is shorter than about 1.3 cm, it can be difficult to card, and when it is longer than about 5.5 cm, it can be difficult to spin with cotton. The cotton can have a length of from about 2 to about 4 cm. The bicomponent fiber has a linear density of at least about 0.7 dtex and preferably at least about 0.9 dtex per fiber and no higher than about 3.0 dtex per fiber. When the bicomponent staple has a linear density above about 3.0 dtex per fiber, the yarn can have a harsh hand, and it can be hard to blend with the cotton, resulting in a poorly consolidated, weak yarn. When it has a linear density below about 0.7 dtex per fiber, it can be difficult to card. For a spun yarn of higher uniformity, it is preferred that the bicomponent staple have a linear density less than about 2.5 dtex per fiber.
[0027] In the spun yarn, the bicomponent staple fiber is present at a level of at least about 20 wt %, preferably at least about 35 wt %, and no more than about 65 wt %, preferably less than 50 wt %, based on the total weight of the spun yarn. When the yarn of the invention comprises less than about 20 wt % polyester bicomponent, the yarn can exhibit inadequate stretch and recovery properties, as indicated by low total boil-off shrinkage. When the yarn comprises more than about 65 wt % bicomponent staple fiber, the blended fibers can be difficult to card.
[0028] In the spun yarn of the invention, the cotton is present at a level of at least about 35 wt % and no higher than about 80 wt %, based on total weight of the spun yarn. Optionally, up to about 30 wt %, based on total weight of the spun yarn, can be other staple fibers, for example poly(ethylene terephthalate) staple.
[0029] When the CI of the bicomponent staple fiber is lower in the range of acceptable values, higher proportions of polyester bicomponent staple fibers can be used without compromising cardability and yarn uniformity. When CD is higher in the range of acceptable values, lower proportions of bicomponent staple can be used without compromising total boil-off shrinkage. In particular, since the fiber blend level, CI, and cardability are inter-related, satisfactory cardability can be retained even with high CI values (for example as high as about 45%) if the amount of bicomponent fiber in the blend is low (for example as low as about 20 wt %, based on total weight of spun yarn). Similarly, since the fiber blend level, CD, and total boil-off shrinkage are inter-related, satisfactory total boil-off shrinkage can be retained even at about 20 wt % bicomponent fiber, based on total weight of spun yarn, if the CD is high, for example at about 55% or more.
[0030] It is preferred that the spun yarn of the invention have a Coefficient of Variation (“CV”) of mass of no higher than about 22%, more preferably no higher than about 18%. Above those values, the yarn can become less desirable for use in some types of fabrics.
[0031] The bicomponent staple fiber can have a weight ratio of poly(ethylene terephthalate) to poly(trimethylene terephthalate) of about 30:70 to 70:30, preferably 40:60 to 60:40. One or both of the polyesters comprising the bicomponent fiber can be copolyesters, and “poly(ethylene terephthalate)” and “poly(trimethylene terephthalate)” include such copolyesters within their meanings. For example, a copoly(ethylene terephthalate) can be used in which the comonomer used to make the copolyester is selected from the group consisting of linear, cyclic, and branched aliphatic dicarboxylic acids having 4-12 carbon atoms (for example butanedioic acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid, and 1,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids other than terephthalic acid and having 8-12 carbon atoms (for example isophthalic acid and 2,6-naphthalenedicarboxylic acid); linear, cyclic, and branched aliphatic diols having 3-8 carbon atoms (for example 1,3-propane diol, 1,2-propanediol, 1,4-butanediol, 3-methyl-1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and 1,4-cyclohexanediol); and aliphatic and araliphatic ether glycols having 4-10 carbon atoms (for example, hydroquinone bis(2-hydroxyethyl) ether, or a poly(ethyleneether) glycol having a molecular weight below about 460, including diethyleneether glycol). The comonomer can be present to the extent that it does not compromise the benefits of the invention, for example at levels of about 0.5-15 mole percent based on total polymer ingredients. Isophthalic acid, pentanedioic acid, hexanedioic acid, 1,3-propane diol, and 1,4-butanediol are preferred comonomers.
[0032] The copolyester(s) can also be made with minor amounts of other comonomers, provided such comonomers do not have an adverse affect on the benefits of the invention. Such other comonomers include 5-sodium-sulfoisophthalate, the sodium salt of 3-(2-sulfoethyl) hexanedioic acid, and dialkyl esters thereof, which can be incorporated at about 0.2-4 mole percent based on total polyester. For improved acid dyeability, the (co)polyester(s) can also be mixed with polymeric secondary amine additives, for example poly(6,6′-imino-bishexamethylene terephthalamide) and copolyamides thereof with hexamethylenediamine, preferably phosphoric acid and phosphorous acid salts thereof.
[0033] There is no particular limitation on the outer cross-section of the bicomponent fiber, which can be round, oval, triangular, ‘snowman’ and the like. A “snowman” cross-section can be described as a side-by-side cross-section having a long axis, a short axis and at least two maxima in the length of the short axis when plotted against the long axis. In one embodiment, the spun yarn of the invention comprises cotton and a bicomponent staple fiber comprising poly(ethylene terephthalate) and poly(trimethylene terephthalate) and having a plurality of longitudinal grooves in the surface thereof. Such a bicomponent staple fiber can be considered to have a “scalloped oval” cross-section which can improve the wicking properties of the polyester bicomponent.
[0034] The polyester bicomponent staple fibers in the spun yarn of the present invention can also comprise conventional additives such as antistats, antioxidants, antimicrobials, flameproofing agents, dyestuffs, light stabilizers, and delustrants such as titanium dioxide, provided they do not detract from the benefits of the invention.
[0035] It is preferred that the bicomponent staple fiber of which the spun yarn of the invention is comprised have a tenacity-at-break of at least about 3.5 dN/tex and no higher than about 5.5 dN/tex. When the tenacity is too low, carding and spinning can be difficult, and when it is too high, fabrics made from the spun yarn of the invention can exhibit undesirable pilling. It is also preferred that the linear density of the spun yarn be in the range of about 100 to 700 denier (111 to 778 dtex).
[0036] Knit (for example circular knit and flat knit) and woven (for example plainwoven and twill) stretch fabrics can be made from the spun yarn of the invention.
[0037] The process of the invention comprises a step of mixing preferably by intimate blending, cotton (which can optionally be combed) with a polyester bicomponent staple fiber having the composition and characteristics described hereinbefore, wherein the bicomponent staple fiber is present at a level of at least about 20 wt % and no more than about 65 wt %, preferably less than 50 wt %, based on the total weight of the blended fibers. The cotton is present at a level of at least about 35 wt % and no higher than about 80 wt %, based on total weight of the blended fibers. Optionally, up to about 30 wt %, based on total weight of the spun yarn, can be other staple fibers, for example poly(ethylene terephthalate) staple.
[0038] Use of bicomponent staple fiber exhibiting follow-the-leader crimp is preferred because such staple is believed to improve carding due to its lower CI level. Correspondingly, it is preferred that the bicomponent fibers in the tow precursor to the staple fiber be ‘in register’ with each other and not be ‘de-registered’.
[0039] The blended fibers are further processed by carding the blended fibers to form a card sliver, drawing the card sliver, doubling and redrawing the card sliver up to 3 times, converting the drawn sliver to roving, and ring-spinning the roving with a twist multiplier of 3 to 5.5 to form the spun yarn having a total boil-off shrinkage of at least about 22%.
[0040] Intrinsic viscosity (“IV”) of the polyesters was measured with a Viscotek Forced Flow Viscometer Model Y-900 at a 0.4% concentration at 19° C. and according to ASTM D-4603-96 but in 50/50 wt % trifluoroacetic acid/methylene chloride instead of the prescribed 60/40 wt % phenol/1,1,2,2-tetrachloroethane. The measured viscosity was then correlated with standard viscosities in 60/40 wt % phenol/1,1,2,2-tetrachloroethane to arrive at the reported intrinsic viscosity values.
[0041] Unless otherwise noted, the following methods of measuring tow Crimp Development and tow Crimp Index of the bicomponent fiber were used in the Examples. To measure tow Crimp Index (“C.I.”), a 1.1 meter sample of polyester bicomponent tow was weighed, and its denier was calculated; the tow size was typically of about 38,000 to 60,000 denier (42,000 to 66,700 dtex). Two knots separated by 25 mm were tied at each end of the tow. Tension was applied to the vertical sample by applying a first clamp at the inner knot of the first end and hanging a 40 mg/den (0.035 dN/tex) weight between the knots of the second end. The sample was exercised three times by lifting and slowly lowering the weight. Then a second clamp was applied at 100 cm down from the inner knot of the first end while the weight was in place between the knots of the second end, the 0.035 dN/tex weight was removed from the second end, and the sample was inverted while maintaining the tension so that the first end was at the bottom. A 1.5 mg/den (0.0013 dN/tex) weight was hung between the knots at the first end, the first clamp was removed from the first end, the sample was allowed to retract against the 0.0013 dN/tex weight, and the (retracted) length from the clamp to the inner knot at the first end was measured in cm and identified as L r . C.I. was calculated according to Formula I. To measure tow Crimp Development (“C.D.”), the same procedure was carried out, except that the 1.1 meter sample was placed—unrestrained—in boiling water for 1 minute and allowed fully to dry before applying the 40 mg/den (0.035 dN/tex) weight.
C.I. and C.D. (%)=100×(100 cm− L r )/100 cm (I)
[0042] To determine the total boil-off-shrinkage of the spun yarns in the Examples, the yarn was made into a skein of 25 wraps on a standard skein winder. While the sample was held taut on the winder, a 10 inch (25.4 cm) length (“L o ”) was marked on the sample with a dye marker. The skein was removed from the winder, placed in boiling water for 1 minute without restraint, removed from the water, and allowed to dry at room temperature. The dry skein was laid flat, and the distance between the dye marks was again measured (“L bo ”). Total boil-off shrinkage was calculated from formula II:
Total B.O.S. (%)=100×( L bo −L o )/ L o (II)
[0043] Using the same sample that had been subjected to the boil-off total shrinkage test, the ‘true’ shrinkage of the spun yarn was measured by applying a 200 mg/den (0.18 dN/tex) load, measuring the extended length, and calculating the percent difference between the before-boil-off and extended after-boil-off lengths. The true shrinkage of the samples was generally less than about 5%. Since true shrinkage constitutes only a very minor fraction of total boil-off shrinkage, the latter is used herein as a reliable measure of the stretch characteristics of the spun yarns. Higher total boil-off shrinkage corresponds to desirably higher stretch.
[0044] The uniformity of the mass of the spun yarns along their length was determined with a Uniformity 1-B Tester (made by Zellweger Uster Corp.) and reported as Coefficient of Variation (“CV”) in percentage units. In this test, yarn was fed into the Tester at 400 yds/min (366 m/min) for 2.5 minutes, during which the mass of the yarn was measured every 8 mm. The standard deviation of the resulting data was calculated, multiplied by 100, and divided by the average mass of the yarn tested to arrive at percent CV.
[0045] Spun yarn tensile properties were determined using a Tensojet (also made by Zellweger Uster Corp.)
[0046] The cardability of the fiber blends used to make the spun yarns in the Examples was assessed with a Trutzschler Corp. staple card for which a rate of 45 pounds per hour (20 kg/hour) was considered “100% speed”. Cardability was rated “Good” if the card could be run at 100% speed with no more than 1 stop in a 40 pound (18 kg) test run, “Satisfactory” for at least 80% speed with no more than 3 stops in a run, and “Poor” if the speed was lower or the number of stops higher than for “Satisfactory”. Stops were generally caused by web breaks or coiling jams.
[0047] To determine available stretch in the fabrics of Examples 6A and 6B, three 60×6.5 cm sample specimens were cut from each of the fabrics in Examples 4A and 4B. The long dimension corresponded to the stretch direction. Each specimen was unraveled equally on each side until it was 5 cm wide. One end of the fabric was folded to form a loop, and a seam was sewn across the width to fix the loop. At 6.5 cm from the unlooped end of the fabric a first line was drawn, and 50 cm away (“GL”) from the first line, a second line was drawn. The sample was conditioned for at least 16 hours at 20+/−2° C. and 65+/−2% relative humidity. The sample was clamped at the first line, and hung vertically. A 30 newton weight was hung from the loop, and the sample was exercised 3 times by alternately allowing it to be stretched by the weight for 3 seconds and then supporting the weight so the fabric was unloaded. The weight was re-applied, and the distance between the lines (“ML”) was recorded to the nearest millimeter. The available stretch was calculated from formula III, and the results from the three specimens were averaged
% Available Stretch=100×( ML−GL )/ GL (III)
[0048] To measure percent growth (a measure of recovery after stretching) in Examples 6A and 6B, three new specimens were prepared as described for the Available Stretch test, extended to 80% of the previously determined Available Stretch, and held in the extended condition for 30 minutes. They were then allowed to relax without restraint for 60 minutes, and the length (“L 2 ”) between the lines was again measured. Percent Fabric Growth was calculated from Formula IV, and the results from the three specimens were averaged.
% Fabric Growth=100×( L 2 −GL )/ GL (IV)
[0049] In the Examples, the cotton was Standard Strict Low Midland Eastern Variety with an average micronaire of 4.3 (about 1.5 denier per fiber (1.7 dtex per fiber)). The cotton and the polyester bicomponent staple fiber were blended by loading both into a dual feed chute feeder, which fed the Trutzschler card. The resulting card sliver was 70 grain/yard (about 49,500 dtex). Six ends of sliver were drawn together 6.5× in each of two passes to give 60 grain/yard (about 42,500 dtex) drawn sliver which was then converted to roving, unless otherwise noted. The total draft in the roving process was 9.9×. Unless otherwise noted, the roving was then double-creeled and ring-spun on a Saco-Lowell frame using a back draft of 1.35 and a total draft of 29 to give a 22/1 cotton count (270 dtex) spun yarn having a twist multiplier of 3.8 and 17.8 turns per inch. When 100% cotton was so processed, the resulting spun yarn had a CV of 22% and a total boil-off shrinkage of 5%.
[0050] Within each bicomponent staple fiber sample, the fibers had substantially equal linear densities and polymer ratios of poly(ethylene terephthalate) to poly(trimethylene terephthalate). No mechanical crimp was applied to the bicomponent staple fibers in the Examples.
[0051] In the Tables, “Comp.” indicates a Comparison Sample, and ‘nm’ indicates ‘not measured’.
EXAMPLE 1A
[0052] Polyester bicomponent staple fiber was made from bicomponent continuous filaments of poly(ethylene terephthalate) (Crystar® 4415-763, a registered trademark of E. I. du Pont de Nemours and Company), having an intrinsic viscosity (“IV”) of 0.52 dl/g, and Sorona® brand poly(trimethylene terephthalate) (Sorona®, a registered trademark of E. I. DuPont de Nemours and Company), having an IV of 1.00, which were melt-spun through a 68-hole post-coalescing spinneret at a spin block, temperature of 255-265° C. The weight ratio of the polymers was 60/40 2G-T/3G-T. The filaments were withdrawn from the spinneret at 450-550 m/min and quenched with crossflow air. The filaments, having a ‘snowman’ cross-section, were drawn 4.4×, heat-treated at 170° C., interlaced, and wound up at 2100-2400 m/min. The filaments had 12% CI (a value believed to be considerably depressed by the interlacing), 51% CD, and a linear density of 2.4 dtex/filament. For conversion to staple fiber, filaments from wound packages were collected into a tow and fed into a conventional staple tow cutter, the blade spacings of which were adjusted to obtain a 1.5 inch (3.8 cm) staple length.
EXAMPLE 1B
[0053] The polyester bicomponent staple fiber from Example 1A was intimately blended with cotton to obtain various weight percents of the two fibers. The blended fibers were carded, drawn, converted to roving, and ring-spun. The resulting spun yarns had the CV and total Boil-Off Shrinkage (“B.O.S.”) values shown in Table I.
TABLE I Staple Total Bicomponent, B.O.S., Spun Yarn wt % Cardability CV, % % Comp. Sample 1A 30 Good 17 18 Sample 1B 40 Good 18 24 Sample 1C 50 Satisfactory 19 34 Sample 1D 60 Satisfactory 22 36 Comp. Sample 1E 70 Poor 25 nm
[0054] Interpolation of the data in Table I shows that total boil-off shrinkage was low when this particular bicomponent staple was less than about 35 wt % of the weight of the spun yarn. The data also show that cardability suffered when the amount of polyester bicomponent staple fiber exceeded about 65 wt %, based on weight of the spun yarn. Uniformity was improved if the proportion of polyester bicomponent was less than 50 wt %.
COMPARISON EXAMPLE 1
[0055] Polyester bicomponent staple fiber was made as described in Example 1A, with the following differences. The weight ratio of 2G-T/3G-T was 40/60, the spinneret had 34 holes, and the resulting filaments had a 4.9 dtex/fil linear density. The CI was 16% and the CD was 50%, but cardability with cotton at levels of 65 wt %, 40 wt %, and even 20 wt % polyester bicomponent staple was very poor, showing the unsatisfactory results obtained when the polyester bicomponent staple had high linear density.
COMPARISON EXAMPLE 2
[0056] Polyester bicomponent staple fiber was made substantially as described in Example 1A, except that the continuous filaments used were drawn 2.6× and had only 3% CI and 29% CD. Cardability was good in a 60/40 polyester/cotton blend, but the boil-off shrinkage of the yarn spun from such a blend was only 15%, showing the inadequate spun yarn properties that result when CD is too low.
EXAMPLE 2
[0057] To make the polyester bicomponent staple fibers used in Examples 3 and 4, poly(ethylene terephthalate) of 0.58 IV was prepared in a continuous polymerizer from terephthalic acid and ethylene glycol in a two-step process using an antimony transesterification catalyst in the second step. TiO 2 (0.3 wt %, based on weight of polymer) was added, and the polymer was transferred at 285° C. and fed by a metering pump to a 790-hole bicomponent fiber spinneret pack maintained at 280° C. Poly(trimethylene terephthalate) (1.04 IV Sorona® brand poly(trimethylene terephthalate)) was solid-phase polymerized, dried, melt-extruded at 258° C., and separately metered to the spinneret pack.
[0058] The FIGURE shows a cross-section of the spinneret pack that was used. Molten poly(ethylene terephthalate) and poly(trimethylene terephthalate) entered distribution plate 2 at holes 1 a and 1 b, were distributed radially through corresponding annular channels 3 a and 3 b , and first contacted each other in slot 4 in distribution plate 5 . The two polyesters passed through hole 6 in metering plate 7 and through counterbore 8 in spinneret plate 9 , and exited the spinneret plate through capillary 10 . The internal diameters of hole 6 and capillary 10 were substantially the same.
[0059] The fibers were spun at 0.5-1.0 g/min per capillary into a radial flow of air supplied at 142 to 200 standard cubic feet per minute (4.0 to 5.6 cubic meters per minute) so that the mass ratio of air:polymer was in the range of 9:1 to 13:1. The quench chamber was substantially the same as that disclosed in U.S. Pat. No. 5,219,506 but used a foraminous quench gas distribution cylinder having similar sized perforations so that it provided ‘constant’ air flow. Spin finish was applied to the fibers with a conical applicator at 0.07 wt % to 0.09 wt % based on fiber weight, and then they were wound onto packages.
[0060] About 48 packages of the resulting side-by-side, round cross-section fibers were combined to make a tow of about 130,000 denier (144,400 dtex), passed around a feed roll to a first draw roll operated at less than 35° C., passed to a second draw roll operated at 85° C. to 90° C. and supplied with a hot water spray, heat-treated by contact with six rolls operated at 170° C., optionally over-fed by up to 14% to a puller roll, and, after application of 0.14 wt % finish based on weight of fiber, passed through a continuous, forced convection dryer operating at below 35° C. The tow was then collected into boxes under substantially no tension and cut to 1.5 inches (3.8 cm) for blending with cotton in Examples 3 and 4. The first draw was 77-90% of the total draw applied to the fibers. Additional spinning and drawing conditions and fiber properties are given in Table II.
TABLE II Drawing: Roll Speeds, Spinning m/min Total Over- Linear Bicomponent Speed, Draw Draw Draw Feed, Density, Tenacity Staple* m/min Feed 1 2 Puller Ratio %** dtex/fiber dN/tex Sample 2A 1800 17.4 41.1 45.7 43.4 2.6 5 2.2 4.1 Sample 2B 1700 22.9 41.1 45.7 43.9 2.0 4 1.8 nm Sample 2C 1500 20.9 56.5 73.2 64.3 3.5 14 1.2 5.0 Comp. Sample 1500 21.3 56.5 73.2 68 3.4 8 1.3 nm 2D Sample 2E 1500 19.7 41.1 45.7 45.7 2.3 0 1.6 3.6 Sample 2F 1500 26.1 58.1 73.2 64 2.8 14 1.4 4.1 Sample 2G 1500 26.1 58.1 73.2 67.7 2.8 8 1.4 nm Sample 2H 1500 17.4 41.1 45.7 41.4 2.6 10 1.4 4.3 Sample 2I 1600 21.7 57.1 73.1 64.2 3.4 14 1.0 4.8 Comp. Sample 1600 23.3 41.1 45.7 44.3 2.0 3 1.6 2.7 2J
EXAMPLE 3
[0061] Selected bicomponent staple samples made in Example 2 were ring spun at a 60/40 polyester/cotton weight ratio to make 22/1 cotton count spun yarns. Bicomponent staple fiber properties, cardability when blended with cotton, and properties of the resulting spun yarns are given in Table III.
TABLE III Bicomponent C.I. C.D. B.O.S. CV, Staple % Cardability % Spun Yarn % % Comp. Sample 2J 9 Good 26 Comp. Sample 3A 20 15 Sample 2B 16 Good 35 Sample 3B 24 19 Sample 2A 28 Satisfactory 49 Sample 3C 34 20 Sample 2H 34 Satisfactory 53 Sample 3D 39 19 Sample 2E 36 Satisfactory 53 Sample 3E 38 22
[0062] Interpolation and extrapolation of the data in Table III show that when CI is below 15%, boil-off shrinkage can be inadequate, and that when CI is as high as about 42%, cardability remains satisfactory.
COMPARISON EXAMPLE 3
[0063] Bicomponent staple Sample 2B was blended with cotton at a polyester bicomponent/cotton weight ratio of 60/40, and the blend was carded and drawn as described hereinabove, but without making a roving. The drawn sliver was air-jet spun into 22/1 yarn on a Murata 802H spinning frame at an air nozzle pressure ratio (N1/N2) of 2.5/5.0, a total draft of 160, and a take-up speed of 200 meters/min. The total boil-off shrinkage of the yarn was only 14%, showing that air-jet spun yarn had unsatisfactory stretch and recovery.
EXAMPLE 4
[0064] Selected bicomponent staple samples made in Example 2 were ring-spun at 60/40 and 40/60 polyester/cotton weight ratios to make 22/1 cotton count spun yarns. Bicomponent staple fiber properties, cardability of the fiber blends, and properties of the resulting spun yarns are given in Table IV.
TABLE IV Bicomponent Bicomponent C.I., C.D., B.O.S., CV, Staple staple, wt % % Cardability % Spun Yarn % % Sample 2I 60 24 Satisfactory 48 Sample 4A 28 18 Sample 2C 60 34 Satisfactory 56 Sample 4B 37 19 Sample 2F 60 28 Satisfactory 49 Sample 4C 31 20 Comp. 60 47 Poor 57 Comp. 38 25 Sample 2D Sample 4D Sample 2G 60 44 Poor 54 Comp. 28 22 Sample 4E Sample 2F 40 28 Good 49 Sample 4F 24 18 Sample 2G 40 44 Satisfactory 54 Comp. 25 22 Sample 4G
[0065] The data in Table IV show that, when CI is above about 42%, carding can be impractically difficult at 60 wt % bicomponent staple but satisfactory at 40 wt % bicomponent staple. Extrapolation of the data shows that at about 20 wt % bicomponent staple having CI as high as about 45%, carding would be good and total boil-off shrinkage and yarn uniformity (CV) would still be acceptable.
EXAMPLE 5
[0066] Women's 3×1 quarter socks with a ½ cushion foot were knit on a Lonati 454J, 108 needle, 4 inch (10 cm) cylinder machine, using only spun yarns from Example 1. Each sock was bleached with aqueous hydrogen peroxide at 180° F. (82° C.) and boarded at 250° F. (121° C.) for 1.5 minutes with dry heat.
[0067] The unload power of the socks was determined as follows. To avoid edge effects, the sock was not cut. It was marked with a 2.5 inch×2.5 inch (6.4 cm×6.4 cm) square, centered on the foot, between the toe and heel. The grips of an Instron tensile tester were placed at the sock foot top and bottom, avoiding the heel and toe and leaving the centered square between the grips so that the test sample had a 2.5 inch (6.4 cm) gauge. Each sample was cycled 3 times to 50% elongation at a speed of 200% elongation per minute. The unload force was measured at 30% remaining available stretch on the 3 rd cycle relaxation and reported in kilograms force and is reported in Table V. In this test, “30% remaining available stretch” means that the fabric had been relaxed 30% from the maximum force on the 3 rd cycle.
TABLE V Knit Sock Fabric Bicomponent Unload Force Sample Spun Yarn Weight, g/m{circumflex over ( )}2 Content, wt % (kg) 5A Sample 1D 180 60 0.10 5B Sample 1C 177 50 0.09 5C Sample 1B 165 40 0.08 Comp. None 127 0 0.04 5E
[0068] The data in Table V show that knit fabric comprising spun yarn of the invention has high fabric unload force and good stretch-and-recovery properties which are retained even in knits made with spun yarns comprising lower levels of the polyester bicomponent staple fiber.
EXAMPLE 6A
[0069] A 3/1 twill fabric was made on an air jet loom with a warp of 100% ring-spun cotton of 40/1 cotton count, reeded to 96 ends/inch (38 ends/cm). The filling yarn consisted of a 22/1 cotton count ring-spun yarn of 40 wt % cotton and 60 wt % of bicomponent staple Sample 2H, inserted at 65 picks per inch (25½ picks per cm) and 500 picks/minute. The fabric was scoured for an hour at the boil and conventionally dyed with direct and disperse dyes. The available stretch was 21%, and the growth was 3.8%, both desirable properties.
EXAMPLE 6B
[0070] Example 6A was repeated but with a spun yarn of bicomponent staple Sample 2E ring-spun at the same blend ratio with cotton, inserted at 45 picks per inch (18 picks/cm). The fabric was scoured for hour at the boil and conventionally dyed with direct and disperse dyes. The available stretch was desirably high at 25%, and the growth was desirably low at 4.6%.
[0071] The yarns produced in the examples and fabrics made therefrom in accordance with the invention were soft and aesthetically pleasing. | The invention provides a spun yarn comprising cotton and a bicomponent polyester staple. The fiber of the invention exhibits unusually high stretch characteristics and has excellent cardability and uniformity. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to orthopedics, in particular, to a crimp used to hold surgical cable after it has been looped around a fractured bone.
BACKGROUND OF THE INVENTION
[0002] It is well known to use surgical cable and crimp assemblies to fix parts of a fractured bone and to join them together until the bone heals. Surgical procedures on and in the vicinity of a bone with closely neighboring nerves, arteries, muscle, ligaments, complicated anatomical structures and delicate areas represent a difficult and time consuming task for the surgeon. Thus it is important for the cable and crimp device to be assembled accurately, minimizing stress, trauma, risk, and injury to a patient while facilitating and shortening the procedure.
[0003] Furthermore it is desirable to maintain the bulk of the cable as well as the joint where the cable is affixed to itself as compact as possible to minimize discomfort and damage to the surrounding tissue.
[0004] Known minimally invasive techniques for such procedures generally involve looping the cable, isolated from the crimp member, about the bone and then inserting a beaded first end of the cable into a cavity of a groove in the crimp member. The groove at the crimp member allows the first end of the cable to slide in place until the bead locks in its final position. The second end of the cable is then inserted through the hole of the crimp member and the cable is tensioned by application of a tensioning tool to the cable through a handle, to a proximal abutment face of the crimp. Once the desired final tension has been established, the set screw is tightened using a screwdriver through the handle, deforming the cable inside the hole. The tensioning tool is then removed and the free end of the cable extending from the proximal abutment face of the crimp is cut off.
[0005] Many of the known tools for performing this procedure require pulling the cable from both ends after the cable has been looped around the bone. To access both ends of the cable as required, such devices require significant spreading of the incision and the tissue along the path of the cable increasing trauma to muscle and other surrounding tissue and making them unsuitable for use in restricted areas. Such devices are disclosed, for example, in U.S. Pat. Nos. 5,649,927 and 6,017,347.
[0006] Other devices such as that described in allow tensioning of the cable by application of a tensioning tool to one of the cable ends and to an abutment face of the crimp by employing a surgical cable factory crimped to one of the holes of the crimp, as those disclosed in U.S. Pat. Nos. 5,423,820, 6,007,268 and 6,387,099. The same effect is achieved by instruments such as that described in U.S. Pat. No. 6,017,347, that use a wire with a beaded end which locks into an end of the crimp preventing the wire from slipping out of the clamp. The bead locks into the end of the crimp preventing the wire from sliding out of the crimp.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is an object of the present invention to provide a compact tool which is easy to assemble and use to secure surgical cable around bone without requiring a large incision and which minimizes the exposure or stripping of musculature away from the bone.
[0008] Furthermore, it is an object of the present invention to provide a cable and crimp assembly that enables the cable to be inserted isolated from the crimp member, and the crimp member to be attached to the surgical cable only after the cable has been looped around the bone.
[0009] The embodiments of the present invention comprise a flexible cable, a crimp member, a set screw, a handle, and a screw-driver. The surgical cable has an enlargement (e.g., a bead) affixed to its first end and the crimp member has a two-part groove, a cable hole for the cable and an oblique threaded hole for a set screw. The groove has a first part including a cavity sized to accept the beaded end of cable. The second part of groove is sized to allow the flexible cable to pass therethrough while stopping the larger, beaded first end of the cable. The cable hole is sized to accommodate the cable while the oblique threaded hole extends to the cable with an abutment, proximal face of the crimp member located near a proximal end of the cable hole.
[0010] The present invention is also directed to a device for binding a cable about a fractured bone to stabilize a fracture comprising a slot including a distal opening sized to receive an enlarged end of a cable and a proximal opening sized to permit the cable to slide therethrough while preventing the enlarged end from passing therethough and a bore sized to slidably receive the cable, the bore extending to a proximal opening in combination with a locking element channel extending to a distal end opening into the bore and a locking element movable into a locking position in which a distal end of the locking element extends into the bore to engage a portion of the cable received therein and lock the cable in a desired position within the bore.
[0011] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Preferred features of the present invention are disclosed in the accompanying drawings, wherein similar reference characters denote similar elements throughout the several views, and wherein:
[0013] FIG. 1 shows a side view of a crimp device according to the first embodiment of the present invention, prior to assembling with a flexible cable;
[0014] FIG. 2 shows a top view of the crimp device of FIG. 1 ;
[0015] FIG. 3 shows a proximal view of the crimp device of FIG. 1 ;
[0016] FIG. 4 shows a perspective view of the crimp device of FIG. 1 ;
[0017] FIG. 5 shows a side view of a disassembled system for fixing a cable about a fractured bone including the crimp device of FIG. 1 ;
[0018] FIG. 6 shows a top view of the system of FIG. 5 ;
[0019] FIG. 7 shows a first perspective view of the system of FIG. 5 ;
[0020] FIG. 8 shows a second perspective view of the system of FIG. 5 ;
[0021] FIG. 9 shows a side view of a set screw for use with a crimp device according to the invention;
[0022] FIG. 10 shows a proximal view of the set screw of FIG. 9 ;
[0023] FIG. 11 shows a perspective view of the set screw of FIG. 9 ;
[0024] FIG. 12 shows a proximal view of a crimp device according a second embodiment of the present invention, prior to assembling with a flexible cable;
[0025] FIG. 13 shows a top view of the crimp device of FIG. 12 ;
[0026] FIG. 14 shows a side view of the crimp device of FIG. 12 ;
[0027] FIG. 15 shows a perspective view of the crimp device of FIG. 12 ;
[0028] FIG. 16 shows a side view of a system for fixing a cable about a fractured bone including the crimp device of FIG. 12 in a partially assembled state;
[0029] FIG. 17 shows a perspective view of the system of FIG. 16 in a partially assembled state;
[0030] FIG. 18 shows a side view of the system of FIG. 16 in a fully assembled state; and
[0031] FIG. 19 shows a perspective view of the system of FIG. 16 in a fully assembled state.
DETAILED DESCRIPTION
[0032] Hereinafter, an apparatus and method for securing surgical cable around a bone according to the preferred embodiment of the present invention will be explained with reference to FIGS. 1-6 . As would be understood by those skilled in the art, the term ‘proximal’ describes a direction approaching a user (e.g., a surgeon) along the item being described while the term ‘distal’ refers to a direction away from the user along the item being described. Thus, the distal end of a cable refers to an end of the cable furthest from an end extending, for example out of the body to a point accessible to a user, along the cable and not to a portion of the cable located physically furthest from the operator.
[0033] As shown in FIGS. 1-4 a binding member 10 according to a first embodiment of the present invention includes an outer surface 12 , a bone facing surface 14 , a distal end 16 and an abutment surface 18 formed at a proximal end 20 thereof. A groove 22 is formed in the binding member 10 extending distally at an angle from a proximal opening 24 in the abutment surface 18 adjacent to the bone facing surface 14 to a distal end 26 . A bore 28 extends from a proximal opening 30 at the distal end 26 of the groove 22 to a distal opening 32 in the distal end 16 . The bore 28 is preferably formed as a simple through hole sized to accept a flexible cable 34 to be held by the binding member 10 . The groove 22 according to this embodiment is formed as a two-part slotted hole open at the outer surface 12 . The proximal opening 24 of the groove 22 is preferably sized so that the cable 34 may slidably pass therethrough while an enlarged first end 36 of the cable 34 is prevented from passing therethrough. The groove 22 may also include a lip 38 (shown in FIG. 2 as the space between the broken lines and the unbroken lines of the groove 22 ) extending substantially around the perimeter thereof sized to permit the cable 34 to pass slidably therethrough while preventing the enlarged first end 36 from passing through. The rest of the groove 22 (i.e., an interior passage thereof) is preferably sized to permit the cable 34 and the enlarged first end 36 to slide therethrough. In addition, the groove 22 includes an enlarged distal opening 40 at the distal end 26 sized to permit the enlarged first end 36 to be inserted into the groove 22 .
[0034] The binding member 10 further comprises a locking element channel 42 extending at an angle from a proximal opening 44 to a distal opening 46 into the bore 28 . As would be understood by those skilled in the art, although the locking element channel 42 is described in conjunction with the disclosed embodiments as receiving a set screw, any number of alternate locking elements may be employed to lock the cable 34 at a desired position in the bore 28 (i.e., to maintain a desired tension thereon) as will be described in more detail below. For example, the locking element may include an interference fit plug, a tube that is crushed, etc. or any other suitable device. As can be seen in FIG. 4 , a proximal part of the channel 42 may include a thread 48 sized to mate with the thread 52 of a corresponding part of a set screw 50 as shown in FIGS. 9-11 . A proximal end of the set screw 50 preferably includes a structure (e.g., a hex recess 51 ) to mate with a known tightening device (not shown) such as a screw driver, hex wrench, etc.
[0035] As shown in FIGS. 5-8 , an apparatus for implanting a binding device 10 includes a mating element 54 including a first channel 56 which, when the element is in a desired position, is aligned with the bore 28 and a second channel 58 including a distal portion 60 which, when in the desired position, is aligned with the channel 42 and a proximal portion 62 which, in this embodiment, extends proximally from a proximal end of the distal portion 60 angled back toward the channel 56 to reduce a profile of the mating element 54 . As would be understood by those skilled in the art, the angle between the proximal and distal portions 62 , 60 , respectively, should preferably be no more than 20° to avoid impeding the operation of the universal joint in a tightening tool to be inserted therethrough as will be described below. Furthermore, a maximum width of the element 54 is preferably no more than 8 mm to minimize trauma to surrounding tissue. The element 54 also includes an abutting surface 64 which, when the element 54 is in the desired position, contacts the abutment surface 18 .
[0036] In use, the cable 34 is first passed around the portion(s) of fractured bone to be stabilized and the enlarged first end 36 is inserted into the groove 22 via the opening 40 . The cable 34 and the enlarged first end 36 are then drawn through the groove 22 until contact between the enlarged first end 36 and the lip 38 prevents the enlarged end 36 from moving further. The second end of the cable 34 is then inserted into the distal opening 32 and passed through the bore 28 out of the proximal opening 30 and into the groove 22 . The second end of the cable 34 is drawn out of the proximal opening 24 and the slack in the cable 34 is drawn out by pulling the cable 34 proximally out of the opening 24 . The second end of the cable 34 is then inserted into the channel 56 and passed therethrough to a known tensioning mechanism (not shown) as the mating element 54 is moved distally over the cable 34 until the abutting surface 64 contacts the abutment surface 18 . The tensioning mechanism is then operated as would be understood by those skilled in the art until a desired tension is placed on the cable 34 . A tightening device including a joint (e.g., a universal joint) allowing the tightening device to navigate the bend in the channel 58 is then inserted through the channel 58 to mate with the hex recess 51 . The set screw 50 is then screwed into the channel 42 until a distal end thereof extends into the bore 28 locking the cable 34 in position therein and maintaining the desired tension in the cable 34 . The second end of the cable 34 may then be released from the tensioning mechanism and the portion of the cable 34 extending proximally from the groove 22 may be cut off and withdrawn from the body.
[0037] As shown in FIGS. 12-19 , a binding member 100 according to a second embodiment of the invention operates in a manner substantially similar to that of the binding member 10 described above. Similar to the binding member 10 , the binding member 100 includes an outer surface 112 , a bone facing surface 114 , a distal end 116 and an abutment surface 118 formed at a proximal end 120 thereof. A groove 122 is formed in the binding member 100 extending distally from a proximal opening 124 in the abutment surface 118 to a distal end 26 . However, in the binding member 100 , the bore 128 does not open into the groove 122 . Rather, the bore 128 extends from a proximal opening 130 in proximal end 120 to a distal opening 132 in the distal end 116 . The bore 128 is preferably formed as a simple through hole sized to accept a flexible cable 34 to be held by the binding member 100 . The proximal opening 124 of the groove 122 is sized so that a cable 134 may slidably pass therethrough while an enlarged first end 136 of the cable 134 is prevented from passing therethrough. The groove 122 also includes a lip 138 extending substantially around the perimeter thereof sized to permit the cable 134 to pass slidably therethrough while preventing the enlarged first end 136 from passing through. The rest of the groove 122 (i.e., an interior passage thereof) is preferably sized to permit the cable 134 and the enlarged first end 136 to slide therethrough. In addition, the groove 122 includes an enlarged distal opening 140 at a distal end 126 thereof sized to permit the enlarged first end 136 to be inserted into the groove 122 . As the bore 128 does not open into the groove 122 , the groove 122 does not need to be angled relative to the outer surface 112 and the bone facing surface 114 . Rather, the groove 122 may extend substantially parallel to these surfaces allowing the thickness of the binding member 100 to be reduced. (please provide some size range for the thickness and width of the binding members 10 and 100 as well as the mating element 54 ).
[0038] The binding member 100 further comprises a locking element channel 142 extending at an angle from a proximal opening 144 to a distal opening 146 into the bore 128 . As described above in regard to the binding member 10 , although the channel 142 is shown as adapted to receive a set screw 50 as shown in FIGS. 9-11 , any number of alternate locking elements may be employed to lock the cable 134 at a desired position in the bore 128 (i.e., to maintain a desired tension thereon). A proximal end of the set screw 50 preferably includes a structure (e.g., a hex recess 51 ) to mate with a known tightening device (not shown) such as a screw driver, hex wrench, etc.
[0039] As shown in FIGS. 16-19 , an apparatus for implanting a binding device 100 includes a mating element 154 including a first channel (not shown) which, when the element 154 is in a desired position, is aligned with the bore 128 and a second channel (not shown) which may include an angled proximal section to reduce the profile of the element 154 similar to the distal portion 60 of the element 54 described above. The distal portion of this second channel, when in the element 154 is in the desired position, is aligned with the channel 142 . The element 154 also includes an abutting surface 164 which, when the element 154 is in the desired position, contacts the abutment surface 118 .
[0040] In use, the cable 134 separate from the binding member 100 is inserted around the bone to be cerclaged as would be understood by those skilled in the art and the enlarged first end 136 is inserted into the groove 122 via the opening 140 . The cable 134 and the enlarged first end 136 are then drawn through the groove 122 until contact between the enlarged first end 136 and the lip 138 prevents the enlarged end 136 from moving further. The second end of the cable 134 is then inserted into the distal opening 132 and passed through the bore 128 out of the proximal opening 130 . The slack in the cable 134 is drawn out by pulling the cable 134 proximally out of the opening 130 and the second end of the cable 134 is inserted into the channel 156 and passed therethrough to a known tensioning mechanism (not shown) as the mating element 154 is moved distally over the cable 134 until the abutting surface 164 contacts the abutment surface 118 . The tensioning mechanism is then operated as would be understood by those skilled in the art until a desired tension is placed on the cable 134 . As described above in regard to element 54 , a tightening device is inserted through the second channel to mate with the hex recess 51 . The set screw 50 is then screwed into the channel 142 until a distal end thereof extends into the bore 128 locking the cable 134 in position therein and maintaining the desired tension in the cable 134 . The second end of the cable 134 may then be released from the tensioning mechanism and the portion of the cable 34 extending proximally from the opening 130 may be cut off and withdrawn from the body.
[0041] The present invention has been described with reference to specific exemplary embodiments. Those skilled in the art will understand that various modifications and changes may be made to the embodiments without departing from the teaching of the invention. These embodiments specification are therefore, to be regarded in an illustrative rather than a restrictive sense and are not intended to limit the scope of the invention which is intended to cover all modifications and variations of this invention that come within the scope of the appended claims and their equivalents. | A device for binding a cable about a fractured bone to stabilize a fracture comprises a slot including a distal opening sized to receive an enlarged end of a cable and a proximal opening sized to permit the cable to slide therethrough while preventing the enlarged end from passing therethough and a bore sized to slidably receive the cable, the bore extending to a proximal opening in combination with a locking element channel extending to a distal end opening into the bore and a locking element movable into a locking position in which a distal end of the locking element extends into the bore to engage a portion of the cable received therein and lock the cable in a desired position within the bore. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to the backrest of a chair in which a back-receiving portion is integrally molded with a frame.
[0002] In a conventional backrest of a chair, to the upper end of a metal back rod which extends from the lower portion of a seat upwards and rearwards, a back plate made of material different from that of the back rod is generally connected directly or indirectly via another material frame.
[0003] However, in the prior art, the back rod is made of material different from those of the frame and the back plate. Therefore, they are connected by screws, and there are disadvantages that it is impossible to shorten manufacturing processes and to decrease cost.
SUMMARY OF THE INVENTION
[0004] In view of the disadvantages in the prior art, it is an object of the present invention to provide the backrest of a chair in which a back plate is integrally molded with a frame which comprises at least part of a back rod, thereby shortening manufacturing processes, decreasing cost and providing comfort of a sitting person when one is reclined.
[0005] According to the present invention, there is provided the backrest of a chair, the backrest being an upright plate made of synthetic resin and comprising a low-rigidity flexible back-receiving portion for receiving the back of a sitting person, a pair of back rods, and pair of outer high-rigidity side frames each of which is spaced from said back-receiving portion via a slit, the lower end of each of said frames being connected to each of the back rods.
[0006] The backrest can be integrally formed from synthetic resin, thereby shortening manufacturing process and decreasing cost. The slits between the back-receiving portion and side frames provide sufficient flexibility and a comfortable chair.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The features and advantages of the present invention will become more apparent from the following description with respect to embodiments as shown in appended drawings wherein:
[0008] [0008]FIG. 1 is a side elevational view of a chair which includes one embodiment of the backrest according to the present invention;
[0009] [0009]FIG. 2 is a rear elevational view of the same;
[0010] [0010]FIG. 3 is a front perspective view of a back plate;
[0011] [0011]FIG. 4 is a left-half rear elevational view of the back plate;
[0012] [0012]FIG. 5 is a side elevational view of the back plate;
[0013] [0013]FIG. 6 is an exploded perspective view of a back rod and a cover;
[0014] [0014]FIG. 7 is an exploded sectional plan view taken along the line VII-VII in FIG. 4;
[0015] [0015]FIG. 8 is an exploded sectional plan view taken along the line VIII-VIII in FIG. 4; and
[0016] [0016]FIG. 9 is a side elevational view of a variation of a flexible connector.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] As shown in FIG. 1, a caster 2 is secured at the end of a leg 1 which radially extends from the center. A support 3 is provided on the center of the leg 1 , and is fixed to a base 4 at the upper end. A backrest 5 is supported by a pair of L-shaped back rods 6 which is pivoted on a base 4 by a horizontal shaft 7 . The backrest 5 and back rods 6 can be inclined at a desired angle from a standing position in FIG. 1 rearwards by a spring-reclining mechanism (not shown) in the base 4 .
[0018] Over the base 4 , a seat 8 is supported via a seat support 9 to move down rearwards with inclination of the backrest 5 and the back rod 6 . At each side of the seat support 9 , an armrest 10 is mounted via a support rod 9 a.
[0019] As shown in FIG. 2, the backrest 5 is integrally molded from synthetic resin and has a rectangular shape near which vertical slits 11 , 11 a are formed. Outside the slits 11 , 11 a , a high-rigidity outer frame 12 is provided, and inside the slits 11 , 11 a , a low-rigidity flexible back-receiving portion 13 is provided. The upper slit 11 is closed at both the upper and lower ends, while the lower slit 11 a is closed at the upper end and opened at the lower end.
[0020] An upper portion 12 a of the side frame 12 is formed like V-shape or an arc to increase thickness and rigidity. A lower portion 12 b of the side frame is a flat front surface and a rear surface which has a plurality of vertical ribs 14 which form a projection 15 . In this embodiment, the number of the rib 14 is three, and the middle rib is the longest.
[0021] Bosses 16 are provided on the rear surface of the lower portion 12 b , and a through-bore 17 is formed at the center of each of the bosses 16 .
[0022] The back rod 6 is made of metal such as Al alloy, and has a concave portion 6 a . The concave portion 6 a is engaged with a projection 15 of the lower portion 12 b of the side frame 12 . The upper end of the back rod 6 is engaged with a stepped portion 12 c between the upper and lower portions 12 a and 12 b . As shown in FIG. 7, a screw 18 through a bore 17 is engaged in a bore 20 of a boss 19 at a position corresponding to the boss 16 , thereby fastening the lower portion 12 b of the side frame 12 to the upper portion of the back rod 6 .
[0023] A low-stepped portion 21 is formed at the rear surface of the upper portion of the back rod 6 . An elastic cover 22 made of synthetic resin or rubber is engaged with the low-stepped portion 21 . The elastic cover 22 has the same shape as the upper portion 12 a of the side frame 12 and substantially the same depth as that of the low-stepped portion 21 . An engagement projection 24 which projects from the front surface of the cover 22 and having an elastically-deformable expanded-diameter portion 23 is engaged in a bore 25 of the back rod 6 , so that the cover 22 is connected to the back rod 6 .
[0024] By connection of the cover 22 to the back rod 6 , the rear end of the bore 20 of the back rod 6 is covered to improve appearance.
[0025] The metal back rod 6 is protected, thereby preventing the back rod 6 from being damaged by a desk, a cabinet etc. The side frame 12 of the backrest 5 forms part or extension of the back rod 6 , thereby acting as frame for supporting the sides of the backrest 5 strongly.
[0026] As shown in FIG. 2, the side frame 12 of the backrest 5 , the back rod 6 and the cover 22 are integrally formed to provide S-shaped good appearance.
[0027] Thickness of the back-receiving portion 13 of the backrest 5 is smaller than that of the side frame 12 , thereby providing flexibility to the back-receiving portion 13 . The intermediate part of the back-receiving portion 13 is cut away to remain three flexible connectors 26 which form a bending portion 27 .
[0028] By the bending portion 27 , the back-receiving portion 13 is divided into upper and lower portions 13 a and 13 b . Thus, when a sitting person reclines against the back-receiving portion 13 strongly, especially in condition that the backrest 5 is inclined rearwards, the bending portion 27 moves rearwards of the other parts, and the upper and lower portions 13 a and 13 b are bent in V-shape. Therefore, even if the backrest 5 is inclined rearwards, the head of the person in a substantially upright position without making the head inclined rearwards, thereby providing comfortable posture to keep his eye to direct forwards.
[0029] Each of the flexible connectors 26 is projected forwards, so that the upper and lower portions 13 a and 13 b are easily bendable with respect to a crest of the flexible connector 26 . If the connector 26 is projected rearwards, vertical tensile strength acts at the crest of the connector 26 to make the upper and lower portions difficult in bending. However, in this embodiment, the upper and lower portions 13 a , 13 b are likely to open.
[0030] In the upper and lower portions 13 a , 13 b of the back-receiving portion 13 , a number of hexagonal openings 28 are formed to increase flexibility of the upper and lower portions 13 a , 13 b . Thinner portions may be formed instead of the openings.
[0031] A bending portion 29 projects rearwards at the upper end of the backrest 5 and increases rigidity of the upper end to act as an upper frame. The bending portion 29 holds the upper end of a cushion 30 and acts as a handle when the chair is moved.
[0032] The lower end of the lower portion 13 b of the back-receiving portion 13 is spaced from the frame 12 by slits 11 , and is connected to the rear end of the seat 8 .
[0033] The cushion 30 covers the whole front surface of the backrest 5 , and the bending portion 29 of the backrest 5 is covered with a winding portion 30 a of the cushion 30 .
[0034] The connector 26 may be formed like a wave as shown in FIG. 9. One connector 26 may be provided in the middle, and two connectors may be provided on both sides of the middle connector. More than three connectors may be provided at suitable distances.
[0035] The foregoing merely relates to embodiments of the present invention. Various modifications and variations may be made by person skilled in the art without departing from the scope of claims wherein: | The backrest of a chair comprises an inner low rigidity flexible back-receiving portion and an outer high-rigidity side frame spaced from the back-receiving portion via a slit. The backrest is integrally molded by synthetic resin, thereby shortening manufacturing process and reducing its cost. Comfort of a sitting person is also attained. | 0 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is being filed concurrently with U.S. patent application Ser. No. 10/612,323 entitled Low Profile Evaporative Cooler Housing; and U.S. patent application Ser. No. 10/612,322 entitled Evaporative Cooler Water Distribution System; and U.S. patent application Ser. No. 10/612,623 entitled Evaporative Cooler Media Housing. Each of the foregoing applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of evaporative coolers, and more particularly to a low profile evaporative cooler.
Evaporative coolers are well know and used in warm dry climates to both raise the humidity and cool the air. Evaporative coolers work by drawing air from outside through a media soaked with water. As the air flows through the soaked media water is evaporated by the outside air thereby lowering the temperature of the air. The cooled air is then directed into the area to be cooled.
An evaporative cooler includes a number of elements all of which are stored in a housing. These elements typically include an air blower; a media pad; a water distribution system; and an electric motor. Evaporative coolers need to be maintained on a periodic basis to replace the media pads and to clean the water distribution system.
There are three traditional approaches to mounting evaporative coolers. One approach is to mount the cooler on the roof in which the cooled air is blown down into the building. This type of cooler is also referred to as a down-draft cooler. The roof mounted cooler provides the advantage of being out of the way and can be easily connected to a duct system to deliver the cooled air. However, maintenance of the roof-mounted coolers is difficult due to access. Additionally, many roof mounted coolers are being banned under local zoning ordinances due to the aesthetic nature of the cooler located on the roof.
Another method of locating evaporative coolers is by hanging the housing from a window or eve. The cooled air is then blown into the area to be cooled through the side of the cooler and is also referred to as a side-draft cooler. The window or eve hung coolers while being more accessible are typically hung from the eves or proximate a window. This approach has a number of disadvantages including blocking the window from use by the cooler. Additionally, the width of the coolers or the distance from which they extend from the building can be up to three feet or more. This extension from the home may not be aesthetically pleasing and also takes up a portion of the yard. Where the coolers are located in more densely populated areas with housing units close to one another the three feet extension may take up a significant portion of the space between the buildings. In addition to making use of the space between the building more difficult to use for garbage and recycling containers, it may make maintenance of the unit more difficult.
A third method of mounting the coolers is to place them on the ground in which the cooled air is blown upwardly. This type of cooler is also referred to as an updraft cooler. This type of cooler has the disadvantage of requiring even greater yard space than the down-draft and side-draft coolers.
Accordingly, it would be desirable to provide an evaporative cooler that could be mounted to a building that would be easy to maintain in small tight areas between buildings. Additionally, it would be desirable to provide an evaporative cooler housing that was not mounted to a roof to avoid local zoning prohibitions. Further it would be desirable to provide an evaporative cooler housing that did not excessively protrude into the yard from the building. Still further it would be desirable to provide a water distribution system that was efficient, compact and required minimal maintenance. It would also be desirable to provide a low profile evaporative cooler that includes centrifugal blowers that provide increased efficiency of the cooler.
SUMMARY OF THE INVENTION
One embodiment relates to an evaporative cooler including a cooler housing having a front panel, an opposing rear panel, and a first and second side. The distance between the first and second side is at least twice the distance between the front and rear panels. A pair of rigid media are located proximate the first and second sides respectively. A centrifugal blower has at least one air inlet facing one of the first and second sides.
In an other embodiment a low profile evaporative cooler comprises a cooler housing including a front panel, an opposing rear panel, and a right and left side extends between the front and rear panels. Each of the right and left sides have at least one opening configured to permit air to enter an interior of the housing. The right and left sides extend a predetermined width between the front and rear panels. The width being less than one half of a length defined by the distance between the right and left sides. A rigid media is located proximate each of the right and left sides. A water distribution system provides water to the rigid media. A centrifugal blower includes a blower housing and a blower wheel. The blower including a pair of air inlets that face the right and left sides respectively.
In a further embodiment, a low profile evaporative cooler extends through a building structure wall having standard spaced studs. The cooler comprises a housing including a front panel and an opposing rear panel configured to be attached directly to the building structure wall. The cooler housing further includes a first and second side extending between the front and rear panels and configured to allow air to enter there through. The front panel has an exposed surface area that is substantially uninterrupted to prevent air from entering there through. A first and second evaporative rigid media pad is located proximate the first and second sides respectively. A pair of centrifugal blowers are located within the housing, each blower having at least one air inlet facing one of the first and second sides. A portion of each of the blowers extends into the wall between the standard spaced studs
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a low profile evaporative cooler.
FIG. 2 is an exploded view of an evaporative cooler.
FIG. 3 is a cross-sectional view of the evaporative cooler taken generally along lines 3 — 3 of FIG. 1 .
FIG. 4 is a cross-sectional view of the evaporative cooler taken generally along lines 4 — 4 of FIG. 3 .
FIG. 5 is a close up view of the cross-sectional view of FIG. 4 taken along lines 5 — 5 of FIG. 4 .
FIG. 6 is a perspective view of the water distribution system of the evaporative cooler.
FIG. 7 is a cross-sectional view taken along lines 7 — 7 of FIG. 3 .
FIG. 8 is a perspective view of the evaporative cooler with a media cabinet tilted outward.
FIG. 9 is a partial cross sectional view of the media cabinet and media tilted outward.
FIG. 10 is a partial cross sectional view of the media cabinet with the media partially removed.
FIG. 11 is an exploded view of an alternative water distribution system.
FIG. 12 is a cross-sectional view of the water distributor of FIG. 11 .
FIG. 13 is a perspective view of the finger plate the water distributor of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , an evaporative cooler 10 is attached to a building or structure 12 . Evaporative cooler 10 includes an evaporative cooler housing 14 , a media assembly 16 , a blower assembly 18 , and a water distribution system 20 . For purposes of convenience, the rear side 22 of evaporative cooler housing 14 will be the side that is in contact with building 12 . Accordingly, front side 24 of the evaporative cooler faces away from the building. The right side 26 and left side 28 of evaporative cooler 10 is on the right and left, respectively as viewed from an observer facing front side 24 . Further, the term “width” as used herein shall refer to the dimension that is perpendicular to the wall of the building 12 . The term “height” shall refer to the up/down dimension, and the term “length” shall refer to the dimension that is both perpendicular to the height and width (see FIG. 1 ).
In the preferred embodiment, evaporate cooler housing 14 is formed from a rear panel 30 , a pair of right and left front panels 40 , 42 , a base 44 , and a top panel 46 . Referring to FIG. 2 . base 44 includes a base plate 47 and four upstanding flanges extending therefrom 48 , 50 , 52 , and 54 to form a water retention cavity or basin. Right and left front panels 40 , 42 , are attached to the front upwards extending flange 50 of base 44 . Rear panel 30 includes right and left panels 56 , 58 having a collinear upper edge 60 and a collinear lower edge 62 . Extending from panels 56 and 58 is a rearwardly extending portion 63 having a panel 64 offset a predetermined distance from panels 56 and 58 by flanges 66 and 68 respectively. The top edge 65 of panel 64 and flanges 66 and 68 is a predetermined distance below the upper edge 60 of portion 63 . Similarly, a bottom edge 69 of panels 64 and flanges 66 and 68 is a predetermined distance above the lower edge 62 of panels 56 and 58 .
The lower portion of panels 56 and 58 is attached to upwardly extending flange 54 of base 44 . Rear panel 30 is formed from a single piece of sheet metal bent to form the various panels 56 , 66 , 64 , 68 , and 58 . It is also possible to form rear panel from two or more pieces of material. For example panels 64 , 66 and 68 could be formed from one or more components and attached or welded to panels 56 and 58 . However, this construction increases the chance of leaking or corrosion at the joints where the full effect of protective coating may be disrupted. The inwardly extending region 63 defined by panel 64 , and flanges 66 , and 68 is configured to fit between two standard spaced studs 70 of building 12 (see FIG. 3 ). The standard spaced studs include 16 inch on center. Of course in other standards are also contemplated. The benefit of providing spacing that can be used with standard spaced studs, allows the evaporative cooler to be installed on new construction or existing buildings without the need to modify the stud configuration. Rear panel 30 further includes an upper cap member 72 having a downwardly extending rear flange 74 and a right and left downwardly extending flanges 76 , 78 . Additionally, upper cap member 72 has an upwardly extending flange 80 . All of the flanges 74 , 76 , 78 , and 80 extend from a center plate member 82 . Downwardly extending flanges 74 , 76 , and 78 are secured to panels 64 , 66 and 68 respectively. The upper edge 81 of flange 80 is collinear with upper edge 60 of panels 56 and 58 when the upper cap 72 is in the assembled position (see FIG. 8 ). Similarly, a lower cap 83 is secured to the lower portion of rear panel 30 . Referring to FIGS. 1 , 2 , and 8 , top panel 46 includes a downwardly extending front and rear flange 84 , 86 and a downwardly extending right and left flange 88 , 90 . Downwardly extending front flange 84 is secured to right and left front panels 40 , 42 and downwardly extending rear flange 86 of top panel 46 is secured to panels 56 , 58 of rear panel 30 as well as to upwardly extending flange 80 of upper cap 72 .
A shell is formed from the base 44 , top panel 46 , rear panel 30 and upper and lower rear panel caps 72 , 74 , and front panels 40 , 42 . A front access door 94 includes a central panel area 96 and a frontwardly extending flange 98 located proximate bottom edge 100 of main panel portion 96 . Additionally, a pair of moveable top covers 102 , 104 cover the right and left media assemblies 108 , respectively. The width of the sides 26 , 28 of evaporator cooler housing 14 is determined by the width of upwardly extending flanges 48 , 52 of base 44 . In a preferred embodiment, the width of base 44 as defined by the distance extending outward from the building 12 is 9.5 inches.
Additionally, the width or distance that flanges 66 and 68 of rear panel 30 extend into the building between studs 70 is 14 inches. It should be noted that in the preferred embodiment, flanges 66 and 68 are integrally formed and part of rear panel 30 and extend substantially perpendicular to panels 56 and 58 . This provides the offset of panel 64 relative to panels 56 and 58 . Panels 64 includes an opening 106 which serves as the air outlet to the evaporate cooler housing 14 . It should also be noted that the front side 24 of housing 14 does not include any louvered openings. However, it is possible in an alternative embodiment to provide louvered openings alone or in any combination with of panels 40 , 42 , and 94 . The air inlets of evaporator housing 14 is accomplished through the right and left media assemblies 16 that are located on the right and left sides 26 , 28 of the housing 14 . Since the right and left media assemblies are identical to one another, each similar component will be identified with a single reference number.
Turning now to FIGS. 2 , 8 and 9 , the media assembly 16 will be described in further detail. Media assembly 16 includes a housing 108 that includes a side louver 110 , a front panel 112 , a rear panel 114 , and a base panel 116 . Extending from base panel 116 is support or leg 118 . Also extending from base panel 116 is an upwardly extending flange 120 having a upwardly extending ledge 122 with a downwardly extending catch flange 124 . Each of the front and rear panels 112 , 114 include a flange 126 , 128 , respectively that extends inwardly into the cavity of the cooler housing 14 a predetermined distance. A media pad 130 is located within the cavity 132 formed by the side louver 110 , front panel 112 and rear panel 114 , and inwardly extending flanges 126 , 128 . In a preferred embodiment media 130 is a rigid media having a width of nine (9) inches, a height of twenty nine (29) inches and a length of eight (8) inches. Each media assembly housing 108 is pivotally attached to upwardly extending base flanges 48 , 52 respectfully as illustrated in FIGS. 8 and 9 . Rigid media as used herein means media formed from corrugated sheets of material that are bonded together to form a rigid structure. Typically the angle of the corrugated flutes are different for adjacent corrugated sheets. An example of rigid media is that sold by Munters under the trade name Celdek. Rigid media also has the characteristic of being substantially rigid.
When the media housing 108 is in an in use position, a bottom edge 133 of leg 118 rests on the inner surface of base plate 47 of base 44 . Media assembly 16 is pivoted from a substantially vertical position to an angled position as shown in FIG. 8 or to a fully horizontal position (not shown) to permit easy access to remove and replace media pad 130 .
Referring to FIG. 4 , water distribution system 20 includes a pump 134 , a water distribution line 136 , and a water diffuser 138 . Pump 134 includes a base 140 having on inlet 142 . Base 140 rests upon plate 47 of base 44 . Water is pumped from base 44 into water distribution lines 136 through a first line 144 . Line 144 splits into two lines 146 , 148 via a splitter 149 . Each of lines 146 , 148 terminate with a nozzle 150 , that is secured to water diffuser 138 .
Water diffuser 138 is illustrated in FIGS. 5 and 6 and positioned as it would be if installed on the right side 26 of evaporative cooler 10 . Water diffuser 138 includes a top panel 156 having a bottom surface 158 that faces downward. A nozzle support plate 160 extends from a front edge 162 of upper plate 156 . Angle support plate 160 extends downward and away from edge 162 . Referring to FIG. 5 , the angle between the support plate 160 and top plate 156 is forty degrees. However, the angle could be between twenty and sixty degrees or any other angle sufficient to direct water from upper plate 156 to a desired location on media 130 . Nozzle 150 is releasably attached to support plate 160 through an opening 164 that is centrally located on support plate 160 . (See FIG. 5 .) Water diffuser 138 further includes a first vertical plate 166 extending downwardly from top plate 156 and substantially perpendicular to top plate 156 . Extending from a lower edge 168 of first vertical plate 166 is a plate 170 that forms an angle of 100 degrees with vertical plate 166 . However, any angle may sufficient so long as it permits a portion of the water to be translated from plate 166 to plate 172 . Plate 170 transitions into a horizontal plate 172 that is substantially parallel to top plate 156 . A downwardly extending flange 174 extends from an edge of horizontal plate 172 . Extending upward from top plate 156 is a first flange 175 , a second flange 176 and a side flange 178 . Additionally extending upwardly from plate 172 is a first flange 180 and a second flange 181 .
The water diffuser 138 that is placed on the right side of evaporative cooler 10 is secured to the front and rear walls 112 , 118 through attaching flanges 173 and 180 , and 176 and 181 , respectively.
Referring to FIG. 5 , water diffuser 138 includes a first water distribution edge 226 that extends from the angled support plate 160 , a second water distribution edge 168 extends from the lower edge of plate 166 , and a third water distribution edge 228 extending from flange 174 . Water diffuser 138 also includes an upwardly extending panel 182 terminating in an upwardly extending flange 184 . Upwardly extending flange 184 abuts against the side panel 110 .
As illustrated in FIG. 4 , line section 148 extends from the splitter to the nozzle 150 . The line 148 extends through an opening 185 in flanges 88 and 90 of top panel 46 . Water is pumped from a water basin defined by base 44 through water distribution lines 136 to the two nozzles 150 located on the respective right and left water diffusers 138 .
Water is sprayed through each nozzle 150 such that it sprays the water against surface 158 of the top plate 156 . Nozzle 150 has an outlet that 0.360 inches in diameter. The size of the nozzle outlet is sufficient to minimize cleaning required due to mineral buildup. Additionally, a single nozzle may be used to wet a rigid media 130 having a length of eight inches and a depth of nine inches. As illustrated in FIGS. 5 and 6 the water hitting surface 158 is split between a first direction toward plate 166 and a second direction toward plate 160 . The water forms a semi-circular pattern such that as the water reaches edges 177 and 178 of plate 156 , the entire edges are covered with water.
The portion of the water flow that hits edge 162 is then directed downward along plate 160 to a lower edge 226 and is deposited onto media 130 at a first position.
The portion of the water flow that hits edge 177 is directed downward along plate 166 to edge 168 . At lower edge 168 the water flow is split. A portion of the water will be deposited onto media 130 at a second position. The remaining water wraps around lower edge 168 and flows along plate 170 and 172 and is finally directed into a third portion of media 130 at flange 174 .
Referring to FIGS. 11–13 another water diffuser 330 is formed from three components, a top panel 332 , an angled panel 334 and a finger insert 336 . The finger insert 336 provides a plurality of channels through which water is routed to ensure that the water flow does not concentrate in a particular region of the diffuser, but rather the water is spread across the entire width of the diffuser 330 . The water diffuser 330 illustrated in FIGS. 11–13 is shown as the right side diffuser. However, a similar mirror image water diffuser may be employed on the left side of the evaporative cooler 10 . Nozzle 150 is secured to angled panel 334 through an opening 338 . Water is sprayed from nozzle 150 such that it hits a substantially horizontal portion 340 of finger insert 336 in such a manner that it directs a portion of the water to the right and a portion of water to the left. In one embodiment, the amount of water directed to the right may be greater than the amount of water directed to the left back toward angled plate 334 . Finger insert 336 includes a top portion 340 that may be substantially horizontal and is attached to the top panel 332 . Extending from a left edge of the top portion 340 is a first fingers plate 342 extending downward and to the right at the same angle as the angled panel 334 . The finger plate 342 includes a cut out region 344 that is aligned with nozzle 150 , and a plurality of fingers 346 that are spaced apart from one another.
Extending from the right side of horizontal top portion 340 is a second set of angled fingers 348 that extends rightward and downward at an angle “a” of forty (40) degrees. In another embodiment, angle “a” is between 20 degrees and sixty degrees. However, the angle may be another value as long as it is sufficient to direct water to the desired location of the top of media 130 . The second set of angled fingers 348 include includes a plurality of fingers 350 that are formed in part in the top portion 340 . A plurality of slits 351 are made in top portion 340 proximate the right edge of the top portion 340 to separate the fingers. The second set of angled fingers 348 include a first group of fingers 352 that extend downwardly at an angle of ninety (90) degrees relative to top portion 340 , while a second group of fingers 354 extend downward and to the right or outward at an angle (a′) of forty (40) degrees. In another embodiment angle a′ could be between 20 degrees and 60 degrees or any other angle sufficient to provide water to be directed toward media 130 .
Angled plate 334 includes a support plate 356 having opening 338 as noted above. Extending from a top edge of support plate 356 is an upwardly extending flange 358 , and extending from a bottom edge of support plate 356 may be a downwardly extending flange (not shown). Also extending from each of the front and rear edges 362 , 364 of support plate 356 is a flange plate 366 , 368 extending upward and to the right that is attached to top plate 332 .
Top plate 332 includes a horizontal plate 370 having a bottom surface 372 and three flanges 374 , 376 , 378 extending upwardly. Top plate 332 further includes a plate 380 extending from the edge 382 distal the angled plate in downward direction. Extending from the bottom edge of plate 382 is a flange 384 extending to the left.
A support bracket 386 is located adjacent plate 380 and has a plate 388 extending below flange 384 that may be in contact with media 130 (See FIG. 12 ). The free ends of fingers 354 , 352 , and 346 are disposed proximate the top of media 130 such that they are spaced apart from one another and spaced along the length of the media 130 . The ends of fingers 354 are proximate the outer or right side of the media 130 , while the ends of fingers 346 are located a predetermined distance from the left or inner side of media 130 . The ends of fingers 352 are located intermediate the ends of fingers 354 and 346 .
Turning to FIG. 7 , the blower assembly includes an upper or first blower 186 and a lower or second blower 187 . In a preferred embodiment, the blowers are inverted relative to one another. The upper blower 186 includes an impeller 188 that is driven by a motor 190 . Air is drawn thought the side inlet 192 and blown out through the outlet 194 . Upper blower 186 is positioned within cavity 132 of evaporative cooler housing 14 such that the exhaust is located on the bottom of the blower 186 . The width of the blowers 186 , 187 as measured along a vector perpendicular to the rear panel is greater than the distance between the rear panels 56 , 58 and front panels 40 , 42 . The blower 186 extends into the extended portion 63 allowing the blowers to be partially located within the wall of the building upon which the cooler is attached.
The lower blower 187 is inverted relative to the upper blower 186 , such that the exhaust outlet 198 is located on the top portion of the blower 187 . The inversion of the lower blower 187 allows the overall width of the housing to be minimal and also minimizes the length of the outlet. Each of the upper and lower blowers 186 , 187 includes a direct drive motor 190 , 191 that is mounted with three ears 194 , 195 . Of course other types of motors or mounting devices may be employed. In the preferred embodiment, each blower is rotary type blower having a height H of 14.75 inches; a width W of 12.75 inches, and a length L of 9.560 inches.
In a preferred embodiment, each of blowers 186 , 187 are rotary blowers having a ⅛ hp motor and a nine inch diameter blower wheel. The inversion of the blowers relative to each other permits an equal flow of air through the right and left sides of the evaporative cooler. Additionally, the position of the blowers permits the air entering the media 130 to head directly into the blower without having to turn ninety degrees. Of course air entering either the top or bottom of the media will enter the blower at an angle. However, greater efficiency is achieved since the inlet or openings of the blowers face the right and left sides of the evaporative cooler and media 130 . The inverted blowers allows double the air flow while still maintaining a nine inch blower wheel. To double the air flow with a single blower, the diameter of blower wheel may have to be increased. An increased blower wheel diameter would require a larger blower housing which in turn would require a large evaporative cooler housing. A larger housing would project further from the building structure. Typically the length of the blower wheel as measured along a longitudinal axis about which the blower rotates is the same as the diameter of the blower wheel. Other types of devices to draw air that may be used in connection with the concepts disclosed herein include a standard propeller type fan blade, a mixed flow slower wheel, and other devices known in the art.
Turning to FIG. 2 evaporative cooler 10 includes an extension 200 that extends between extension panel 64 of rear panel 30 through the wall of the building 12 . Extension 200 is formed of a rigid preformed plastic sheet that has four sides, 202 , 204 , 206 and 208 . The extension is movable from a flattened position in which sides 202 and 204 are adjacent sides 206 and 208 to a rectangular position that has the same periphery as the opening 106 of extension panel 64 . Other types of extensions are also contemplated such as an accordion style member or an extension formed from two separate components that slide relative to one another. The ability to easily adjust the width of the extension permits the grill to fit adjacent the inner wall of the building while allowing the rear panel of the housing to be adjacent the outer wall of the building. In one embodiment the rear panel extension portion has a width of 4.2 inches. This width is sufficient to house a portion of the blower and to be affixed if desired to the studs, but does not extend beyond the width of the wall (the distance between the inner and outer walls of the building or structure). While 4.2 inches is the width of the extension in one embodiment, other widths may be employed.
A first and second frame member 210 , 212 are positioned on either side of the extension 200 . Each frame member 210 , 212 includes an outer frame member 214 , 216 and an inwardly extending flange 218 , 220 . Each end 222 , 224 of extension 200 fits about the inwardly extending flanges 218 , 220 respectively. Extension 200 may be secured to the inwardly extending flanges 218 , 220 with a mechanical or adhesive fastener. The inner frame member 214 is attached directly to the rear panel 30 with mechanical fasteners or other fastening means. The second frame member 216 may be attached to the inside wall of building 12 . Extension 200 may be sized to extend from the first frame member 214 through the wall to the second frame that is located proximate the inside wall of the building. Finally a grill is secured to the second frame member 216 to provide both a decorative finish to the evaporative cooler and provide means for directing the air flow into the building.
In one embodiment, the width of the housing as measured from the building structure that the rear panel contacts is 9.5 inches. The length of the housing is 42 inches. This represents a length to width radio of over 4. The extension portion of rear panel extends 4.5 inches into the building as measured from the outside wall of the building. Accordingly, in one embodiment, the total width available for housing the blower is 14 inches. The extension of 4.5 inches into the wall of the building ensures that the extension will not significantly protrude into the building structure when the building structure utilizes standard 2×4 construction with minimal thickness outer wall and inner wall materials. Most evaporative coolers utilizing a centrifugal blower having a blower wheel typically have a width to length ratio of 1. Low profile coolers typically have a ratio of between 1.5 and 2.0. However, the lower profile coolers with a width under 24 inches are limited by the size of the blower and therefore the amount of air can be cooled by the cooler as measured in cubic feet per minute is limited. The use of side air entry allows the blowers to extend up to the front wall further minimizing the area required to store the blowers and thereby allowing for a bigger blower wheel then if a media pad was placed proximate the front panel. Additionally, the two side rigid media 130 can be eight inches in length to provide increased efficiency over a thin media pad of aspen wood or other thin media. Efficiency in the low profile evaporative cooler is gained by providing dual side air inlets through media pads that does not require the air to turn ninety degrees to enter to the centrifugal blowers. Additionally, efficiency in the low profile evaporative cooler is gained by providing two blowers and allowing both sides of the blowers to receive air from the right and left side inlets. The size of the blowers that can be used is further restricted for a low profile evaporative cooler if the blowers are to be located in part in the wall between two 16 inch on center studs. By locating the blowers one on top of the other in an inverted fashion, the blower outlet can be upto 14 inches in length and still have the inlets directly face the side inlets. The low profile evaporative cooler is further enhanced by locating the motors to run the blowers proximate the inlets to allow the height of the evaporative cooler housing to minimized. Alternatively the motors may be located between the inlets on the right and/or left sides of the blowers. If the motors are placed between the blowers and the front and or rear walls the width of the housing must increase. Similarly, if the motors are placed above or below the blowers, the height of the housing must increase. By employing two centrifugal blowers as described above, it is possible to achieve an actual cooled airflow of over 1200 cfm with a housing width of under 15 inches. In one embodiment the housing extends under 10 inches from the outer building structure wall. Further, the combined cooled airflow achieved with a housing extending 10 inches or less from the outer building structure may be over 1700, 1750, or 1800 cfm or greater.
It is important to note that the construction and arrangement of the elements of the evaporative cooler housing as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present invention 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, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. 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 preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the appended claims. | A low profile side inlet evaporative cooler including a housing having a housing length width at least twice the housing width. A centrifugal blower draws air through two side inlets through and through a rigid evaporative cooling media. | 5 |
BACKGROUND OF THE APPLICATION
This invention relates to a method of treating fresh fruit, and in particular to a method of treating fresh fruit so that the fruit will maintain its fluids when canned as a shelf product.
When fresh fruit is picked and packed, it often is frozen until needed. However, when fresh fruit is frozen, the juice separates from the fruit when thawed, causing up to 50% loss in weight. The fruit juice can be separated or stabilized, but it cannot be placed back into the fruit itself. The fruit, without the juice as part of the fruit, shrinks and presents a less attractive, less desirable finished product. I do not know of any current method of treating fresh fruit before it is frozen which will enable the juice to stay in the fruit when the fruit is thawed.
Present methods of treating fresh fruit include adding sugars and stabilizers to the fruit prior to freezing. The stabilizers tend to thicken the juice when the fruit is thawed. The sugar is added to increase the solids content of the fruit. However, neither the sugar not the stabilizer will help keep the juice in the fruit; the juice will still separate from the fruit when it is thawed.
Fresh fruit is also pasteurized or sterilized when packed. This produces a good tasting product, but does not aid in keeping the juice in the fruit and the fruit looses its firmness.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a method for treating fresh fruit prior to processing of the fruit to prevent separation of the juice from the fruit when the fruit is used.
Another object is to provide such a method which will produce fruit which will be firm.
Another object is to provide such a method which is easy to carry out.
Another object is to provide such a method which will not use a significant amount of energy.
These and other objects and advantages will become apparent to those skilled in the art in light of the following disclosure and accompanying drawings.
In accordance with the invention, generally stated, my method includes soaking fresh fruit, preferably after it has been washed and sliced or cubed, for an extended period of time in a calcium enriched aqueous solution to gel the pectin in the fruit. Preferably, the calcium solution also contains citric acid and preservatives. After the fruit has been soaked from about 2 to about 6 weeks (preferably for about 4 weeks), it is removed from the calcium solution and rinsed. After the fruit has been rinsed, coloring agents, sweeteners, stabilizers, flavorings, citric acid, and preservatives can be added to the fruit. The fruit also can be pasteurized and hot packed.
The solution includes water, calcium salt, citric acid, and preservatives, preferably sodium benzoate and potassium sorbate. The solution includes about 92% to about 98% water, about 1% to about 7% calcium, about 0.2% to about 0.3% citric acid, and about 0.4% to about 0.8% preservatives. Preferably, the solution is about 95% water, about. 4% calcium, about 0.2% citric acid, and about 0.64% preservatives.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As noted above, conventional methods of treating fresh fruit prior to freezing or processing cause the juice to separate from the fruit when the frozen fruit is thawed. My method substantially prevents this problem. When fruit is treated in accordance with my method, the juice will not separate from the fruit when the fruit is processed.
My method consists of soaking the fruit in a calcium enriched solution having preservatives for an extended period of time, preferably about 2 to about 6 weeks. Most preferably, the fruit is soaked for about 4 weeks in the solution. The calcium enriched solution includes water, a calcium salt, citric acid, and preservatives, preferably sodium benzoate and potassium sorbate. Although any form of calcium may be used in my solution, calcium chloride is preferred. When the fruit is soaked in my solution, the pectin in the fruit reacts with the calcium so that the pectin in the fruit is gelled. With the pectin gelled in the fruit, the fruit may be frozen, and upon thawing, the juice will remain in the fruit. The calcium treated fruit also can be hot packed or otherwise processed without losing its juice.
Preferably, the freshly picked fruit is washed, sorted, and sliced, cubed or chopped prior to being placed in the bath.
When a 100 lb. fruit/solution mixture is used, the mixture includes, by weight, 60-75 lbs. fresh fruit, 25-40 lbs. water, 0.5-3 lbs. calcium salt, 0.05-0.2 lbs. citric acid, 0.05-0.1 lbs. sodium benzoate, and 0.05-0.1 lbs. potassium sorbate. Preferably, 68.75 lbs. of fresh fruit is soaked in 29.7375 lbs. water, 1.25 lbs. calcium salt, 0.0625 lbs. citric acid, 0.1 lbs. sodium benzoate, and 0.1 lbs. potassium sorbate.
By weight, the solution, itself, is about 92% to 98% water, about 1 to 7% calcium salt, about 0.2% to 0.3% citric acid, about 0.4% to 0.8% preservatives. The preservatives preferably are about 0.2% to 0.4% sodium benzoate and about 0.2% to 0.4% potassium sorbate, by weight of the solution. The preferred solution is about 95.16% water, about 4% calcium salt, about 0.2% citric acid, about 0.32% sodium benzoate, and about 0.32% potassium sorbate.
When the fruit has soaked in the bath sufficiently long, about 2 to 6 weeks, and preferably about 4 weeks, the fruit is removed from the solution and rinsed. With appropriate changes to the solution, the fruit can be stored indefinitely in the solution. After the fruit has been rinsed, coloring agents, sweeteners, stabilizers, flavorings, citric acid, and other preservatives may be added. The treated fruit is then pasteurized and hot packed. The finished product is shelf stable and ready for direct addition to dairy or bakery products.
Any suitable fresh fruit can be processed by this invention, including strawberries, peaches, raspberries, etc.
Suitable calcium salts include calcium chloride, calcium oxide, calcium carbonate, calcium phosphate, calcium lactate, etc.
The various additives may be added in any combination desired. For example, placing the soaked fruit in a sweetener syrup increases the solids content of the fruit which gives the fruit a better texture in ice cream.
My method has several benefits over the prior method. When most fruit is picked and packed, it is frozen. When frozen fruit is thawed, most of the liquid separates from the fruit causing up to 50% loss of weight. The fruit then shrinks and makes a less attractive finished product. When the fruit is stored in my solution, the calcium causes the pectin to gel, making the fruit firm. Since the pectin is gelled in the fruit, the juice does not tend to separate from the fruit during processing. Hence, there is little to no loss of weight and little to no shrinking of the fruit. The extra firmness of the fruit produces a better finished product after going through processing equipment. The product will stay firm, allowing one to make a hot pack shelf stable product with better fruit identity. Because my method does not include freezing and storing of the fruit frozen, less energy is consumed by my method. When the fruit is soaked in a sweetener solution, the solids content of the fruit will increase, making the fruit firmer. This will make the fruit a superior ice cream fruit.
My method of treating fresh fruit provides a finished product which gels the pectin in the fruit and retains the juices in the fruit upon thawing of the fruit. My method does not rely on freezing of the fruit and storing the fruit frozen. It thus uses less energy then current methods.
EXAMPLE 1
Fresh strawberries are picked, washed, and sorted. In carrying out my method, 250 lbs. of strawberries were placed in 55 gallon drums. A solution of 6 lbs of calcium chloride, 0.45 lb. of citric acid, 0.2 lb. or sodium benzoate, 0.2 lb. potassium sorbate, and 143 lbs. of water was added to the strawberries. The fruit is stored for two weeks to one year at refrigerated or room temperature (about 68° F.). When needed, the fruit can be rinsed and used, or further processed as in the same manner as frozen fruit. The fruit, after being soaked in the solution, is firmer than fresh fruit.
EXAMPLE 2
Fresh peaches are picked, washed and sorted. The peaches can be sliced, shopped or cubed. 250 lbs of peaches are placed in 55 gallon drums. The solution of Example 1 is used to cover the peaches. The peaches can be soaked and stored in the solution for two weeks to one year at refrigerated or room temperatures, and without freezing the fruit. The fruit can be rinsed and used in the same manner as frozen fruit. Further, the peaches are firmer than fresh peaches after having been soaked in the solution.
EXAMPLE 3
Fresh raspberries were picked, washed and sorted, They were treated in the same manner as the peaches and the strawberries.
As variations within the scope of the appended claims may be apparent to those skilled in the art, the foregoing description is set forth only for illustrative purposes and is not meant to be limiting. | A method of treating fresh fruit which gels the pectin in the fruit to keep the fruit's juice from separating from the fruit during subsequent processing. The method includes soaking the fruit in a calcium enriched solution for an extended period of time, i.e. from about 2 to about 6 weeks. | 0 |
FIELD OF INVENTION
[0001] The present invention relates generally to computers. More particularly, the present invention relates to computer programming.
BACKGROUND
[0002] Computer systems have become a virtual necessity for the operation of any relatively large organization. For financial, membership or even asset information, there is no other device capable of tracking the activities of geographically diverse organizational operations administered by different people, possibly using different languages.
[0003] A computer system used by an organization will typically be provided with a number of databases to administer and track organizational activities. For example, one database may be provided for financial information (e.g., accounts receivable, accounts payable, etc.), another database may be provided to track progress towards organizational objectives (e.g., manufactured product, raw materials, etc.) and still another database may be provided to track organization membership (e.g., human resources, etc.).
[0004] A respective server may be provided as an interface between organizational members and the organizational databases. Where the needs for different parts of the organization are different (e.g., language), then an application specific interface (API) may be used to standardize a server interface to a common format.
[0005] Due to changing business conditions or otherwise, software components and systems eventually become outdated and must be updated or replaced. While the process may be relatively simple in the case of a personal computer, the process becomes considerably more complicated in networked systems having many servers and dependent applications that rely upon those servers. Because of the importance of servers and server systems, there is a continuing, ongoing need for better methods of updating computer systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 depicts a computer system for deploying software at a customer's site in accordance with an illustrated embodiment of the present invention;
[0007] FIG. 2 depicts an analysis model of the objects constituting an image installer in accordance with an illustrated embodiment of the present invention;
[0008] FIG. 3 depicts an interactive window displayed on a screen of a computer for welcoming a user to an install mode of the image installer;
[0009] FIG. 4 depicts an interactive window displayed on a screen of a computer for identifying a configuration file;
[0010] FIG. 5 depicts an interactive window displayed on a screen of a computer for identifying a directory in which to install deployed software;
[0011] FIG. 6 depicts an interactive window displayed on a screen of a computer for identifying a location on a disk in which to install support files;
[0012] FIG. 7 depicts an interactive window displayed on a screen of a computer showing a summary of data entered during the install mode;
[0013] FIG. 8 depicts an interactive screen of a computer for welcoming a user to an install mode of the image installer;
[0014] FIG. 9 depicts an interactive screen of a computer for identifying a configuration file;
[0015] FIG. 10 depicts an interactive screen of a computer for identifying a directory in which to install deployed software;
[0016] FIG. 11 depicts an interactive screen of a computer for identifying a location on a disk in which to install support files; and
[0017] FIG. 12 depicts an interactive screen of a computer showing a summary of data entered during the Install Mode.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] While this invention is susceptible of an embodiment in many different forms, there are shown in the drawings and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention. It is not intended to limit the invention to the specific illustrated embodiments.
[0019] Embodiments of the present invention include a computer system for deploying software at a customer's site in accordance with illustrated embodiments of the present invention. The software system may be used in a broad range of computing applications and environments. While the system may have application to many different computer systems, the software loading system may be of particular value in the case of a computer system with many servers such as an automatic call distribution system. It should be understood that the system can be used in virtually any multi-tier computer system. As used herein, a multi-tier computer system is a computer system with a multitude of inter-dependent servers.
[0020] When multi-tier software systems must be updated, software suppliers will often build a software tool referred to as a software or application installer. An application installer is a custom application that is loaded onto a computer and that installs software applications on top of preexisting software applications that had previously been set up by IT personnel responsible for the computer system.
[0021] A variation of an application installer is a software or virtual appliance. A virtual appliance differs from an application installer in that it is provided with its own operating system environment. A virtual appliance, as with the application installer, is self-contained in the sense that it is oblivious to the environment in which it is installed.
[0022] In the past, the use of pre-built software installers or virtual appliances has often produced unpredictable results since it was likely that the software product to be installed had not been fully tested in the intended environment. For example, the end user may have very different IT security, network and machine setup standards than that of the software developer. Products successfully tested by the software developer often did not work as expected once deployed into the customer's environment due to different preexisting conditions (e.g., security policies, network settings, additional software, etc.).
[0023] In addition, many pre-built software installers or virtual appliances often require the input of information for each and every machine on which the software is to be installed. The requirement for additional information often causes input errors and can lead to misconfigured deployments where consistent information is not provided.
[0024] To address these problems, a system in accordance with the present invention provides an interface that collects information about the specific environment of deployment within the destination system. Processing features within the system process the collected information to produce an interface profile that allows a software system with a number of servers to be properly configured and deployed with a minimum of or no user interaction.
[0025] A software installation system can include at least three components: a virtual appliance automation tool (VAAT), a deployment wizard (DW), and an image installer (II). In general, the software installation system is provided by a software developer for use by an organization in automatically installing software within a computer system. The VAAT may reside on a host operated by the software developer while the deployment wizard and image installer may exist in the form of CDs or files transferred between the host of the software developer and host of the organization.
[0026] Turning now to FIG. 1 , the image installer 12 can be used to deploy virtual appliances at a customer site. A user can run a deployment wizard 14 , which can produce a deployment configuration XML file 16 based upon the destination environment. While running the deployment wizard 14 , the user can determine which virtual appliances are to be deployed.
[0027] The image installer 12 can read the deployment configuration XML file 16 to determine which virtual appliances or images need to be deployed on the current destination machine. The VAAT 18 can create a Virtual Appliance Index that lists which DVD 20 or 22 or other computer medium contains which virtual appliance. The image installer 12 can look to the Virtual Appliance Index to determine which DVD 20 or 22 contains the virtual appliances 24 , 26 that are to be deployed. The image installer 12 can then prompt the proper DVD 20 or 22 for the virtual appliances 24 , 26 that are to be deployed and deploy the virtual appliances 24 , 26 to the host machine 28 . Once a virtual appliance 24 , for example, is deployed, the network settings and machine name of the virtual appliance 24 deployed can be changed.
[0028] In embodiments of the claimed invention, virtual appliances can be deployed in an operating system that employs virtualization software. For example, virtual appliances can be deployed in a high end VMWare ESX operating system. VMWare (Virtual Machine Software) is a company that develops proprietary virtualization software products, and ESX is an enterprise-level software that runs directly on server hardware without requiring an additional underlying operating system. In further embodiments, virtual appliances can be deployed into a host operating system that runs Windows or Linux. In embodiments where Windows or Linux is employed, an image installer can be used for internal testing only.
[0029] While operating within the system 10 , the image installer 12 can have several responsibilities. First, the image installer can provide a user interface (UI) installer that can be run on diverse host operating systems. For example, and as discussed above, the UI installer can run on Windows, Linux, and VMWare ESX. As will be explained herein, when the UI installer runs on VMWare ESX, the system can use a console interface because ESX does not have a windowing environment. Therefore, the image installer can provide a console interface that can be used on operating systems that don't have windowing environments.
[0030] The image installer can provide three basic modes of operation: install mode, modify mode, and uninstall mode. Each mode of operation will be discussed in further detail herein.
[0031] If the host system is running on a Linux or Windows operating system, the image installer can give the option to silently install a VMWare server. If a VMWare server is already present in the system, the image installer can give the option to use the existing VMWare server.
[0032] Before operation, the image installer can perform several prerequisite checks. First, the image installer can verify that a proper operating system version is running. Next, the image installer can determine that the host machine has enough physical memory to handle the virtual appliances that are to be deployed onto that system. Finally, the image installer can verify that the host machine has enough CPU Cores to handle the virtual appliances that are to be deployed on that system.
[0033] The image installer can reassemble virtual appliances that are deployed onto various DVDs or other computer medium. Specifically, the image installer can combine, for example, split 500 MB files into a single file, uncompress the combined file, and extract the uncompressed file into several virtual appliance files.
[0034] The image installer can deploy virtual appliances to a host operating system and coordinate with a virtual appliance script running in the virtual appliance and the virtualization software on the host machine to change the network settings of the deployed virtual appliance. Further, the image installer can coordinate with virtualization software to copy the deployment configuration file to a deployed virtual appliance. The image installer can read the deployment configuration XML and virtual appliance index XML files to determine which virtual appliances to deploy and from which DVD to pull the virtual appliance. Finally, the image installer can prompt a user to insert the appropriate DVD when deploying virtual appliances.
[0035] As described above, the image installer can support three installation modes: install, modify, and uninstall. In the event that a virtual appliance must be re-deployed, this can be done using the image installer via two operations: an uninstall operation followed by an install operation.
[0036] During the install mode, the image installer can deploy new virtual appliances to a host machine. Specifically, the image installer can read the deployment configuration XML file to determine which virtual appliances are to be deployed onto the host machine. The image installer can then read the virtual appliance index XML file to determine from which DVD to pull to pull the virtual appliance. The virtual appliance files are then transferred to the host operating system.
[0037] Once transferred to the host operating system, the virtual appliance can be registered with virtualization software, and the virtual appliance is started. When the virtual appliance starts up, the image installer can communicate with a virtual appliance script to change the network settings (e.g., administrative password, setting to use DHCP) and machine name of the virtual appliance to match the data provided in the deployment configuration file. The image installer can also use the virtualization software to place a copy of the deployment configuration file on the virtual appliance.
[0038] Once the network settings are changed, the image installer can be activated to read the deployment configuration file. The image installer can use the data from the deployment configuration file to complete the installation and configuration of the virtual appliance. The image installer can use the host names and IP addresses that are not known at the time the virtual appliance is created to complete the configuration of the software on the deployed virtual appliance.
[0039] After a first virtual appliance is employed, a user can use the same process to deploy any number of virtual appliances that are to be installed on the host machine. In embodiments of the present invention where the host operating system is Windows or Linux as opposed to ESX, the image installer can silently support installing the virtualization software if it cannot be found during the install mode.
[0040] During the modify mode, the image installer can compare the original deployment configuration file with a modified version of the deployment configuration file. The image installer can note any virtual appliances that are being added to or removed from the current host machine. For each removed virtual appliance, the image installer can unregister the virtual appliance with the virtualization software and delete the virtual machine from the disk. For each added virtual appliance, the image installer can follow the procedure described above with respect to the install mode to deploy the new virtual appliance.
[0041] During the uninstall mode, the image installer can completely uninstall any deployed virtual appliances. Specifically, the image installer can stop the virtual appliances, unregister the virtual appliances from the virtualization software, and delete all of the virtual appliance files from the disk. The image installer can remove all of the virtual appliances that it has deployed.
[0042] In embodiments of the claimed invention where the host operating system is Windows or Linux, the image installer will not uninstall the virtualization software. The virtualization software can be uninstalled from Windows or Linux using Add/Remove programs native to Windows or Linux.
[0043] With respect to the deployment configuration file, which is produced by the deployment wizard, the deployment configuration file can contain configuration information for the system. Additionally, the deployment configuration file can be used by the image installer to perform at least the following tasks: checksum verification, host name verification, and virtual appliance configuration.
[0044] The checksum verification task includes the image installer determining if a selected file is valid. Specifically, the checksum verification task includes summing the ASCII value of all characters found in the deployment configuration file and comparing that value with the value of the image installer's internal calculation of the value. If the values are the same, the installation process can proceed. If the values are not the same, the image installer can prevent the user from proceeding.
[0045] The host name verification task includes the image installer running a search in the deployment configuration XML file to find a name that matches the name of the local host machine. If the name of the host machine is found in the XML file, then the image installer can determine which virtual appliances are to be deployed onto the host. If the name of the host machine is not found in the XML file, an error can be displayed to the user. In this event, the user cannot proceed with installation.
[0046] The virtual appliance configuration task can be carried out if the name of the host machine is found in the XML file. In this event, the image installer can obtain at least the following information from the deployment configuration XML file: the file name and directory name of the virtual appliance image to be deployed, the machine name to be changed to on the virtual appliance, the administrative password to be used on the virtual appliance, and a setting to change network settings to use dynamic host configuration protocol (DHCP) on the virtual appliance. If DHCP is not enabled, then the image installer can obtain the following additional information from the XML file: the IP address to use on the virtual appliance, the subnet mask to use on the virtual appliance, the default gateway to use on the virtual appliance, the domain name system (DNS) to use on the virtual appliance; and optional DNS to use on the virtual appliance. The image installer can use this information obtained from the XML file to set the machine name and network settings when deploying the virtual appliance.
[0047] In embodiments of the present invention, a Macrovision InstallAnywhere tool can be used to build the install project for the image installer. This approach has several advantages over a manual install process. First, the InstallAnywhere tool can build install projects that can work in either a GUI or console mode depending on the environment where it is invoked. Accordingly, a user-friendly interface for live users can be provided as well as a means of running the installer in an automated way for silent installs. Second, the InstallAnywhere tool has multiplatform capabilities. In this regard, a single installer can be built that can run on Windows, Linux, or VMWare ESX host operating systems.
[0048] Turning now to FIG. 2 , the image installer 12 can include at least three objects: an image installer object 30 , host components 32 , and Java classes 34 .
[0049] In FIG. 2 , the image installer object 30 represents the InstallAnywhere installer project. The image installer object 30 can be the main control object for the image installer 12 . The image installer object 30 can provide the user interface, both GUI and console, for the image installer 12 . Further, the image installer object 30 can provide the basic functionality for checking prerequisites, installing files, and performing silent installs. The image installer object 30 can control the flow of the installation process and, based on conditions, determine if and what actions to run during the install.
[0050] The host components 32 can include installers, tools, and scripts that are invoked on the host operating system. Host components 32 can include, for example, installers for silently installing a VMWare server, GNU tools for uncompressing virtual appliance images, and Perl scripts that are used to interact with virtualization software. The host 32 components will be described in further detail herein.
[0051] The InstallAnywhere tool can provide interface hooks for running Java code during the installation process. The Java code can perform the complicated tasks that can't be done natively in the InstallAnywhere tool, including, for example, reading XML files, prompting a user for console input, and validating console input. The Java classes 34 will be described in further detail herein
[0052] The external interface of the image installer in accordance with the present invention includes a user interface that asks for user inputs. In embodiments of the present invention, the user interface can be a GUI. In alternate embodiments, the user interface can be a console interface.
[0053] An exemplary series of interactive windows displayed on a GUI of the image installer during the install mode is shown in FIGS. 3-7 . Those of skill in the art will understand that the displayed windows may include additional or alternate windows than those depicted in FIGS. 3-7 . Those of skill in the art will further understand that interactive windows for the modify and uninstall modes come within the spirit and scope of the present invention and are in accordance with the windows depicted in FIGS. 3-7 .
[0054] FIG. 3 depicts a window welcoming a user to an install mode of the image installer. The welcome window is shown first.
[0055] FIG. 4 depicts a window for identifying a configuration file. A user can browse to a deployment configuration file. When the user selects a deployment configuration file, the image installer can perform the checksum verification and host name verification tasks as described above. That is, the image installer can analyze the selected deployment configuration file to determine if the checksum of the selected file is valid and to determine if the name of the local host machine is listed in the deployment configuration file. If errors are encountered, a popup dialog can be shown. In this event, a user is not allowed to proceed with the installation.
[0056] FIG. 5 depicts a window for identifying a directory in which to install deployed software. A user can browse to a directory in which he or she wants to install the virtual appliance(s). The image installer can place each virtual appliance that is being deployed onto the local host machine into its own directory under the directory selected by the user. A user cannot proceed if an invalid directory is selected.
[0057] FIG. 6 depicts a window for identifying a location on a disk in which to install support files. The support files, including the deployment configuration file, must be installed on a disk. A user can browse to a location on the disk in which to install the support files.
[0058] FIG. 7 depicts a window showing a summary of data entered during the install mode. The summary window is the last shown. The information shown in the summary window can include, for example, a list of virtual appliance or images that are to be deployed onto the local host machine.
[0059] An exemplary series of interactive screens displayed on a console interface of the image installer during the install mode is shown in FIGS. 8-12 . Those of skill in the art will understand that the displayed screens may include additional or alternate screens than those depicted in FIGS. 8-12 . Those of skill in the art will further understand that interactive screens for the modify and uninstall modes come within the spirit and scope of the present invention and are in accordance with the screens depicted in FIGS. 8-12 .
[0060] The console interface can capture the same information captured in the GUI as described above. To start the image installer in console mode, a user can use a “-i console” command line. Console mode can be used on VMWare ESX, which does not include a windowing environment. Console mode can also be used on Windows or Linux host operating systems.
[0061] FIG. 8 depicts a screen welcoming a user to an install mode of the image installer in console mode. The welcome screen is shown first.
[0062] FIG. 9 depicts a screen for identifying a configuration file. The configuration identifying screen can display a default location in which a deployment configuration file may be located. The user can enter an alternate location or accept the default location. When the user selects the location of the deployment configuration file, the image installer can perform the checksum verification and host name verification tasks as described above.
[0063] FIG. 10 depicts a screen for identifying a directory in which to install deployed software. The directory identifying screen can display a default location in which to install the virtual appliance(s). The user can enter an alternate location or accept the default location. The image installer can place each virtual appliance that is being deployed onto the local host machine into its own directory under the directory selected by the user. A user cannot proceed if an invalid directory is selected.
[0064] FIG. 11 depicts a screen for identifying a location on a disk in which to install support files. The location identifying screen can display a default location in which to install the support files. The user can enter an alternate location or accept the default location.
[0065] FIG. 12 depicts a screen showing a summary of data entered during the install mode. The summary screen is the last shown.
[0066] A threading model for the image installer as would be understood by those of skill can be created and managed by the InstallAnywhere tool. All installation operations can be performed on a single thread. Further, the thread can be created when the image installer is started from the XML configuration file and can terminate when the image installer completes. The lifecycle of the thread can exist whether the image installer is running in GUI mode, console mode, or silent mode.
[0067] With respect to the java classes included in the image installer, custom code components, which are part of the InstallAnywhere tool, can be written in Java and can be used to perform complicated tasks that can't be completed in the InstallAnywhere tool. The custom code components can gather information and monitor the progress of the installation process.
[0068] The Java custom code can be built by extending a CustomCodeAction interface. This interface defines two methods: install and uninstall, that can be overridden. The InstallAnywhere tool can call either the install or uninstall method depending on what type of operation is being done. Various exemplary types of Java custom code in accordance with the present invention will now be described herein.
[0069] ConsoleInput Java custom code, for example, can be used to gather user information from a console prompt. This class can be used to obtain the path to the deployment configuration XML file and to obtain the location in which to store virtual appliance images, as described above.
[0070] GetOSProperties Java custom code, for example, can be used to gather system information. This class can be used to obtain the name of the local host machine and operating system used.
[0071] XMLCheck Java custom code, for example, can check the deployment configuration file for a checksum value, as described above. The checksum value can be stored in an InstallAnywhere variable. This code can also search the deployment configuration file for the name of the local host machine and indicate whether the name was found.
[0072] CheckSumRule Java custom code, for example, can validate the deployment configuration file checksum, described above. CheckSumRule can compare the CheckSum value with its own calculation of the value. If the two values are the same, the comparison succeeds. If the two values are not the same, the comparison fails, and an error message can be displayed.
[0073] PerformXPathQuery Java custom code, for example, can gather virtual appliance configuration information from the deployment configuration XML file. The code can copy the appropriate virtual appliance image to the appropriate destination on a local disk, set any permissions that are needed, and pass the configuration information to a respective Perl script.
[0074] PerformXPathQueryConsole, for example, is the console version of the PerformXPathQuery script. In addition to the functionalities described above, the PerformXPathQueryConsole Java custom code can perform a cloning function for ESX virtual appliance images in lieu of copying the images.
[0075] A Common object, for example, can contain data classes for VMImage and VMImageList.
[0076] A JDPAPI object, for example, can be used to decrypt passwords within the image installer. This object can be used when setting an administrator's password inside a deployed virtual appliance, for example.
[0077] A ModifyImages object, for example, can be called during the uninstall mode. The ModifyImages object can compare the images in the existing deployment with the images in a new deployment file and make any adjustments necessary. In embodiments of the present invention, this object can run quickly so unnecessary lag time is not experienced in the installer. A ModifyImagesConsole is the console version of the ModifyImages object.
[0078] Finally, a RemoveImages object, for example, can be used during the uninstall mode to find and remove all installed images.
[0079] With respect to the host components included in the image installer, the host components can be installed by the image installer on a local disk. These components can aide in preparing the VMware-server and corresponding virtual appliance images. Various types of exemplary host components in accordance with the present invention will now be described herein.
[0080] A VMware Server Windows Installer Package, for example, can contain software to run virtual appliance images. If not already installed on a host operating system, this component can be installed silently by the image installer.
[0081] A VMware vmPerl API Windows Installer Package, for example, can contain API to send and receive information to and from the guest operating system. If not already installed on the host operating system, this component can be installed silently by the image installer.
[0082] A VMware RPM Package Manager, for example, can contain software to run virtual appliance images. This component can also contain the VMware vmPerl Scripting API component. If not already installed on the host operating system, the WMware RPM Package Manager can be installed silently by the image installer.
[0083] A post VMware-server installation script for Red Hat Linux, for example, can set up the default configuration and license without any prompts.
[0084] The deployment configuration XML file can be packaged into an ISO file, for example, and mounted as a CD on the guest operating system. This utility can give the guest operating system the ability to access the XML file.
[0085] A utility to uncompress the virtual appliance images from a CD or DVD can result in a file that is a tar ball. A utility to uncompact the tar ball can result in consumable virtual appliance image files.
[0086] A Merge Perl Scripts component, for example, can be used as the main scripts to deploy a virtual appliance and can include several steps. First, split image files from the DVDs can be merged into a single file. Then, the merged file can be uncompressed following by untarring the uncompressed file to install the virtual appliance to its final destination on the host machine. Then, a deployment configuration ISO file can be mounted inside of the virtual appliance so the deployment configuration file can be seen inside the virtual appliance. The deployment configuration file can be mounted as a CD ROM. The virtual appliance can be registered, started, and receive network settings. Next, the virtual appliance script can change network settings, machine name, and an administrator password. The virtual appliance script can shut down the virtual appliance, and the CD ROM drive on the virtual appliance can be reconfigured to point back to the physical CD drive.
[0087] Finally, a Remove Perl Scripts component can be used to remove a virtual appliance. This component can stop the virtual appliance if it is running, unregister the virtual appliance from the virtualization software, and delete all of the virtual appliance files.
[0088] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus or method illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. | A method, apparatus, and software are provided for deploying at least one virtual appliance to a deployment site of a multi-tier computer system. The method includes reading a deployment configuration file to identify at least one virtual appliance to deploy, transferring the identified at least one virtual appliance to the computer system, registering the at least one virtual appliance with a virtualization software of the computer system, changing the network settings of the virtualization software to match the deployment configuration file, placing a copy of the deployment configuration file on the virtualization software, and the virtualization software installing the identified at least one virtual appliance on the computer system. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a universal serial bus (hereinafter referred to as ‘USB’) memory device having a 5 pin USB connector. More particularly, the present invention relates an USB memory device which may be directly used in various types of 5 pin US port portable (mobile) terminals including a smart phone and a smart pad and a method of manufacturing the same.
[0003] The present invention also relates to an USB memory device which includes a 5 pin USB connector provided at one side thereof and a 4 pin USB connector provided at the other side thereof such that the USB memory device can be connected to a PC type 4 pin USB port, such as a desk top computer, as well as various types of portable terminals to facilitate memory storage and data transmission between terminals of different pin types, and a method of manufacturing the same.
[0004] 2. Description of the Related Art
[0005] A USB refers to one of bus standards used for data communication between a computer and a peripheral device. A USB memory device is a portable storage device using a flash memory inserted into a USB port, and acquires data from various electronic devices, such as a PC supporting a USB protocol, so that a user may reuse the data.
[0006] However, since a USB memory device according to the related art includes a 4 pin USB connector, the USB memory device is not suitable for a mobile terminal using a 5 pin USB port, such as a mini type port or a micro type port.
[0007] In order to solve this problem, as shown in FIG. 1 , a USB host cable 10 according to the related art has been developed in which a 4 pin USB is provided at one end of the USB host cable 10 and a 5 pin USB connector is provided at an opposite end of USB host cable 10 so that a USB memory device can be connected to a mobile terminal.
[0008] However, the related art has a limitation in that a separate cable is required to connect the USB memory device to the portable terminal.
[0009] Accordingly, the development of a USB memory device which can be directly used in a portable terminal is needed.
[0010] Since the USB memory device according to the related art is not suitable for the portable terminal, although data transfer can be freely achieved between PCs using only the USB memory device, there is a limitation in data transfer between the PC and the portable terminal using only the USB memory device. To transfer data between the PC and the portable terminal, there is needed a cable provided at one side thereof with a 4 pin USC connector and at the other side thereof with a 5 pin USB connector.
[0011] Accordingly, the development of a USB memory device available in both of the PC and the portable terminal is required.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a USB memory device having a 5 pin USB connector which may be directly used for a portable terminal.
[0013] Another object of the present invention is to provide a USB memory device having both a 5 pin USB connector and a 4 pin USB connector, which is applicable to both of a PC and a portable terminal to freely transfer data between the PC and the portable terminal.
[0014] To accomplish these objects, according to one aspect of the present invention, there is provided a universal serial bus (USB) memory device including: at least one 5 pin USB connector; a memory to write data received from the 5 pin USB connector or reading out stored data to transmit the data to the 5 pin USB connector; and a controller electrically connected to the 5 pin USB connector and the memory to control data transmission between the 5 pin USB connector and the memory, wherein the 5 pin USB connector comprises a power terminal, a ground terminal, a D+ terminal, a D− terminal, and an ID terminal, and the ID terminal is connected to the ground terminal so that the 5 pin USB connector is grounded.
[0015] The power terminal of the 5 pin USB connector may be electrically connected to a power control terminal of the controller, the D+ terminal of the 5 pin USB connector may be electrically connected to a D− control terminal of the controller, the D− terminal of the 5 pin USB connector may be electrically connected to a D+ control terminal of the controller, and the ground terminal and the ID terminal of the 5 pin USB connector may be electrically connected to a ground control terminal of the controller, respectively.
[0016] The universal serial bus memory device may further include at least one 4 pin USB connector including a second power terminal, a second ground terminal, a second D+ terminal, and a second D− terminal, wherein the 4 pin USB connector is electrically connected to the controller so that data transmission from the memory is controlled by the controller.
[0017] The 4 pin USB connector may be electrically connected to an electrical connection node between the 5 pin USB connector and the controller 120 .
[0018] According to another aspect of the present invention, there is provided a method of manufacturing a universal serial bus (USB) memory device, the method including: forming a 5 pin USB connector including a power terminal transferring V CC power, a ground terminal transferring a ground signal, a D+ terminal and a D− terminal transferring a data signal, and an ID terminal selectively transferring a client signal and a host signal to an external device, and transferring a signal in such a manner that an external device connected to the 5 pin USB connector is recognized as a client when the ID terminal is connected to the ground terminal so that the 5 pin USB connector is open without being connected to a mobile terminal, and transferring a signal in such a manner that the external device connected to the 5 pin USB connector is recognized as a host when the 5 pin USB connector is shorted with the mobile terminal; forming a controller configured to manage data input/output of the memory while controlling an operating system of the portable terminal connected to the 5 pin USB connector to recognize a USB memory device, and electrically connected to the 5 pin USB connector and the memory to controls data transmission between the 5 pin USB connector and the memory; forming a memory configured to write data from the 5 pin USB connector or read out stored data to transmit the data to the 5 pin USB connector, freely store or delete data, and maintain the data even if power is turned off.
[0019] The 5 pin USB may be electrically connected to the controller in such a manner that the power terminal of the 5 pin USB connector is electrically connected to a power control terminal of the controller, the D+ terminal of the pin USB connector is electrically connected to a D− control terminal of the controller, the D− terminal of the pin USB connector is electrically connected to a D+ control terminal of the controller, and the ground terminal and the ID terminal of the 5 pin USB connector are electrically connected to a ground control terminal of the controller, respectively.
[0020] The method may further include forming a 4 pin USB connector including a second power terminal, a second ground terminal, a second D+ terminal, and a second D− terminal, and wherein the 4 pin USB connector may be electrically connected to the controller so that data transmission from the memory is controlled by the controller.
[0021] The controller may control data transmission between the 4 pin USB connector and the memory or controls the memory to record and store data from the 4 pin USB connector, the power terminal of the 4 pin USB connector may be electrically connected to a connection node between the power terminal of the 5 pin USB connector and the power control terminal of the controller, the D+ terminal of the pin USB connector may be electrically connected to a connection node between the D+ terminal of the 5 pin USB connector and the D− control terminal of the controller, the D− terminal of the 4 pin USB connector may be electrically connected to a connection node between the D− terminal of the 5 pin USB connector and the D− control terminal of the controller, and the ground terminal of the 4 pin USB connector may be electrically connected to a connection node between the ground terminal of the 5 pin USB connector and the ground control terminal of the controller.
[0022] As described above, since the USB memory device according to the present invention may be directly connected to the mobile terminal, the USB memory device can receive and store data from the mobile terminal without a separate cable or auxiliary device.
[0023] That is, since the USB memory device of the present invention may be directly connected to the separate cable or auxiliary device, only the USB memory device can store data of the mobile terminal and transfer the data of the mobile terminal to other mobile terminals.
[0024] In addition, the USB memory device may include not only the first USB connector suitable for the mobile terminal, but also the second USB connector suitable for the PC, data transfer between the PC and the mobile terminal can be achieved only using the USB memory device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view illustrating a configuration of a USB host cable according to the related art;
[0026] FIG. 2 is a view illustrating constituent elements of a USB memory device and connection relationship of the constituent elements according to an embodiment of the present invention; and
[0027] FIG. 3 is a view illustrating constituent elements of a USB memory device and connection relationship of the constituent elements according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to accompanying drawings. However, the present inventive concept may be embodied in many different forms and should not be limited to the embodiments set forth herein.
[0029] Accordingly, the present invention is not limited to the specific embodiment, but the embodiment includes all modifications, equivalents, and substitutes belonging to the technical scope of the embodiment without departing from the spirit of the embodiment.
[0030] The same reference numbers are used throughout the drawings to refer to the same or like parts.
[0031] FIG. 2 is a view illustrating constituent elements of a USB memory device and connection relationship between the constituent elements according to an embodiment of the present invention.
[0032] As shown in FIG. 2 , the USB memory device 100 of the present invention is provided with at least one 5 pin USB connector 110 , and a memory 130 and a controller 120 are electrically communicated with the 5 pin USB connector 110 .
[0033] In detail, the 5 pin USB connector 110 is connected to a USB port of a mobile terminal having a 5 pin USB port to input/output data. The mobile terminal having the 5 pin USB port includes a controller controlling and managing USB transmission on a bus by an operation program supporting a USB standard protocol and being set in a host mode or a client mode, and the 5 pin UBS port for connecting a peripheral device of a USB standard.
[0034] For reference, the USB port of the mobile terminal corresponds to the USB connector of the USB memory. If the USB connector is a male connector, the USB port may be a female connector.
[0035] The 5 pin USB connector 110 includes a power terminal a, a D− terminal b, a D+ terminal c, an identification (ID) terminal d, and a ground terminal e, and functions of the power terminal a, the D− terminal b, the D+ terminal c, the ID terminal d, and the ground terminal e will be described in a following table 1. The ID terminal d is connected and shorted with the ground terminal e so that a controller of the mobile terminal is activated by a host controller.
[0036] This is because a signal is transferred so that an external device connected to the USB connector is recognized as a client when the ID terminal d is open without being connected to the ground terminal e, and the signal is transferred so that the external device connected to the USB connector is recognized as a host when the ID terminal d is shorted.
[0000]
TABLE 1
Terminal name
Function
Power terminal
Transfer V cc power
D− terminal
Transfer data signal
D+ terminal
Transfer data signal
ID terminal
Transfer client/host signals to external
device
Ground terminal
Transfer ground signal
[0037] Meanwhile, the memory 130 writes and reads data. In detail, the memory 130 writes data received from the 5 pin USB connector or reads out stored data and transfers the read data to the 5 pin USB connector.
[0038] It is preferable that the memory 130 may freely store or remove data, and maintain the data even at power-off. For example, the memory 130 may include a flash memory.
[0039] Meanwhile, the controller 120 controls an operating system of the portable terminal connected to the 5 pin USB connector 110 to recognize a USB memory device, and manages data input/output of the memory 130 . In detail, the controller 120 is electrically connected to the 5 pin USB connector 110 and the memory 130 and controls data transmission between the 5 pin USB connector 110 and the memory 130 .
[0040] Referring to FIG. 2 , the 5 pin USB connector 110 is electrically connected to the controller 120 .
[0041] In this case, the power terminal a of the 5 pin USB connector 110 is electrically connected to a power control terminal 1 of the controller 120 , the D− terminal b of the 5 pin USB connector 110 is electrically connected to a D+ control terminal 3 of the controller 120 , a D+ terminal of the 5 pin USB connector 110 is electrically connected to a D− control terminal 2 of the controller 120 , and the ID terminal d and the ground terminal e of the 5 pin USB connector are electrically connected to a ground control terminal 4 of the controller 120 , respectively.
[0042] Particularly, the D+ terminal c and the D− terminal b of the 5 pin USB connector 110 are electrically connected to the D− control terminal 2 and the D+ control terminal 3 of the controller 120 , respectively, and transmit data from the USB connector 110 to the controller 120 .
[0043] Accordingly, the control of data transmission by the controller 120 will be described in detail. The D− control terminal 2 and the D+ control terminal 3 of the controller 120 are electrically connected to the D+ terminal c and the D− terminal b of the 5 pin USB connector 110 , respectively.
[0044] In this case, the controller 120 may receive data from the 5 pin USB connector 110 , and transmits the received data to the memory 130 to control so that the data are recorded in the memory 130 . To the contrary, the controller 120 may reads out data stored in the memory 130 to control so that the data are transmitted to the 5 pin USB connector 110 .
[0045] Since the USB memory device 100 according to the embodiment of the present invention mentioned above is suitably used for the mobile terminal having the 5 pin USB port and may be directly connected to the mobile terminal, the USB memory device may receive and store the data from the mobile terminal without a separate cable or auxiliary device.
[0046] Further, the USB memory device 100 according to the embodiment of the present invention may store data of the mobile terminal and transfer the data to other mobile terminals using only the USB memory device without the separate cable or auxiliary device.
[0047] FIG. 3 is a view illustrating constituent elements of a USB memory device and connection relationship between the constituent elements according to another embodiment of the present invention.
[0048] Referring to FIG. 3 , the USB memory device according to another embodiment of the present invention may further include at least one 4 pin USB connector 140 having a second power terminal 10 , a second D+ terminal 20 , a second D− terminal 30 , and a second ground terminal 400 in addition to the configuration of the USB memory device according to the embodiment of the present invention.
[0049] That is, the USB memory device 100 may be used not only for a mobile terminal having a 5 pin USB port, but also for a PC by further including the 4 pin USB connector 140 suitable for a PC.
[0050] The 4 pin USB connector 140 is electrically connected to the controller 120 so that data transmission is controlled between the 4 pin USB connector 140 and the memory 130 by the controller 120 .
[0051] Thus, the controller 120 can control data transmission between the 5 pin USB connector 110 and the memory 130 and data transmission between the 4 pin USB connector 140 and the memory 130 , and the memory 130 can record data from the 4 pin USB connector 140 and can transmit stored data to the 4 pin USB connector 140 .
[0052] Referring to FIG. 3 , an electrical connection configuration between the 4 pin USB connector 140 and the controller 120 will be described in detail below. The 4 pin USB connector 140 may be electrically connected to an electrical connection node between the 5 pin USB connector 110 and the controller 120 .
[0053] In detail, a second power terminal 10 of the 4 pin USB connector is electrically connected to a connection node between the power terminal a of the 5 pin USB connector 110 and the power control terminal 1 of the controller 120 . The second D+ terminal 20 of the 4 pin USB connector 140 is electrically connected to a connection node between the D+ terminal c of the 5 pin USB connector 110 and the D− control terminal 2 of the controller 120 . The second D− terminal 30 of the 4 pin USB connector 140 is electrically connected to a connection node between the D− terminal b of the 5 pin USB connector 110 and the D− control terminal 3 of the controller 120 . The second ground terminal 40 of the pin USB connector 140 is electrically connected to a connection node between the ground terminal e of the 5 pin USB connector 110 and the ground control terminal 4 of the controller 120 .
[0054] As described above, since the USB memory device 100 according to another embodiment of the present invention includes the 4 pin USB connector 140 as well as the 5 pin USB connector 110 , the USB memory device 100 is suitably used to the PC as well as the mobile terminal having the 5 pin USB port.
[0055] Therefore, the USB memory device 100 according another embodiment of the present invention may be used as a mobile disk in the PC as well as the mobile terminal, and the user may store the data from the mobile terminal and transfer the stored data to the PC.
[0056] Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Disclosed are a universal serial bus (USB) memory device having a 5 pin USB connector which may be directly used for a portable terminal and a method of manufacturing the same. The USB memory device includes: at least one 5 pin USB connector; a memory to write data received from the 5 pin USB connector or reading out stored data to transmit the data to the 5 pin USB connector; and a controller electrically connected to the 5 pin USB connector and the memory to control data transmission between the 5 pin USB connector and the memory, wherein the 5 pin USB connector comprises a power terminal, a ground terminal, a D+ terminal, a D− terminal, and an ID terminal, and the ID terminal is connected to the ground terminal so that the 5 pin USB connector is grounded. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of forming electrodes of a semiconductor device, and particularly to a method in which adhesive property to a Si substrate is high and is suitable when it is used for forming a back electrode of power devices.
2. Description of the Related Art
Conventionally, the method of manufacturing laminated metal electrode wherein a titanium film, a nickel film, and a gold film are formed sequentially on a semiconductor wafer using sputtering process or vapor deposition process has been well-known. However, there is a disadvantage such that a strong film stress occurs in a nickel film and decreases the adhesion strength between a laminated metal electrode and a wafer, so that particularly a peel-off occurs at the interface between the titanium and the semiconductor wafer.
For the countermeasure, a method of obtaining an anchor effect and high adhesion strength by polishing wafer surface in a specific form as well as, for example, a method of reducing a nickel film stress as disclosed in the gazette of Japanese patent Application Laid-open No. 167890-1990 have been well-known.
However, the former method has a disadvantage such that the increased number of steps incurs higher cost and the polishing incurs crack failure.
On the other hand, the latter method can make the stress of a nickel film to less than 3×108 N/m 2 by controlling argon pressure to more than 12 mTorr and the substrate to a temperature of 100° C.-250° C., thus achieving a certain degree of effect. However, when the single wafer sputtering system or the like is used continuously and industrially, the temperature inside the system increases to 250° C. more. As a result, the nickel film stress becomes higher, thus causing peel-off at the bonded portion as well.
SUMMARY OF THE INVENTION
The present invention was made to overcome the above problems. It is an object of the present invention to provide a method of forming electrodes of a semiconductor device which can increase the adhesion between a Si substrate and a metal electrode without especially increasing the number of steps such as the formation of a surface with a roughness of specific shape on a Si substrate and without specially decreasing the stress of the nickel film.
In order to achieve the above object, the electrode forming method according to the present invention is characterized in that; in an electrode forming method for a semiconductor device which includes the steps of forming a contact metal film on a silicon substrate surface after subjecting it to a cleaning process using a reverse sputtering process by argon ion, and forming a nickel film as a soldering metal on the contact metal film, the number of the argon atoms per unit area at the interface between the silicon and the contact metal film is controlled .to a predetermined value, that is, below 4.0×10 14 atoms/cm 2 .
More concretely, when the substrate temperature for the formation of the contact metal film is less than about 350° C., the number of argon atoms per unit area at the interface is adjusted to below a predetermined value by controlling the output of the reverse sputtering during the cleaning process.
In addition, when by controlling the substrate temperature during the formation of the contact metal film to about more than 300° C., utilizing the diffusion, and the argon atom distribution at the interface between the silicon substrate and the contact metal film is dispersed, whereby the number of argon atoms per unit area at the interface is controlled to less than the predetermined value.
In this invention, the present inventors found the fact as a result of many experiments and considerations that in the substrate cleaning process being performed as a preliminary treatment to form a contact metal film on the surface of a silicon substrate, when the oxide film on a silicon substrate in dry process is intended to remove, the adhesion between the silicon substrate and the metal electrode is decreased remarkably. In the substrate cleaning process, it was found that argon atoms introduced into the silicon substrate are a factor which decreases the adhesion strength at the interface between the silicon substrate and the contact metal film in comparison with the strong film stress of a nickel film. The present invention was made based on the fact that vigorous studies by the present inventors found that the adhesion strength can make strong by controlling the amount of argon atoms at the interface.
That is, the natural oxide film grown on the surface of a silicon substrate is removed to clean the surface thereof by bombarding inert argon gas against the silicon substrate. In the cleaning process, the ion bombardment damages the surface of a silicon substrate and the silicon (Si) on the top surface of it makes into amorphous.
In this state, when a metal for ohmic contact such as titanium (Ti) is deposited, Si diffuses into Ti layer in the Si/Ti interface to form a Si-Ti amorphous layer, whereby the bonding of the Si/Ti interface is strengthened. However, at a substrate temperature of about 350° C. or less during the Ti deposition process, argon atoms (Ar) existing in the surface of the Si substrate cannot be easily diffused into Ti layer, but concentrate in the interface between the Si substrate and the Si-Ti amorphous layer.
Experiments and considerations by the present inventors found first that there are relationships between the amount of argon atoms which concentrate in the interface between the silicon substrate and the Si-Ti amorphous layer, and the bonding strength between an electrode and Si. In other words, a strong bonding between an electrode and Si can be maintained by making the amount of argon atoms in the interface to a predetermined value or less than about 4×10 14 atoms/cm 2 with respect to the film stress of the nickel film.
The amount of argon atoms which concentrate in the interface can be adjusted by controlling the output of argon ion reverse sputtering during the substrate cleaning process to control the energy of the argon ions.
On the other hand, the present invention was made based on the result that the present inventors found through many experiments and considerations that the adhesion strength between an electrode and Si can be increased by controlling the substrate temperature during sputtering when an electrode is formed by sputtering.
That is, when a metal for ohmic contact, for example, titanium (Ti) is deposited in the state in which the top surface of a silicon substrate is made into amorphous using cleaning process, argon atoms (Ar) existing on the surface of a Si substrate can be diffused into Ti layer during Ti depositing process at a substrate temperature of more than 300° C. Therefore Ti can be readily reacted with amorphous Si in the Si/Ti interface without concentrating argon in the interface between the Si substrate and the electrode layer, whereby a strong bonding between electrode and Si can be maintained.
According to the present invention, argon atoms in the interface between the silicon substrate and the contact metal film are controlled in amount, which is introduced into a silicon substrate during the substrate cleaning process and affects adversely to the adhesion strength between the electrode and Si. In other words, by the condition of the argon ion reverse sputtering in the substrate cleaning process, or the substrate temperature to at least 300° C. during the contact metal formation is controlled merely there is the excellent effect that the amorphous layer of Si and the contact metal is functioned as a strong bonding layer of the interface between electrode and Si substrate, whereby the adhesion strength between the si substrate and the metal electrode can be improved effectively.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross sectional view showing a semiconductor device (DMOS element) manufactured by applying an embodiment according to the present invention.
FIG. 2 is a structural diagram of a sputtering system used for the embodiment according to the present invention.
FIGS. 3(a) to 3(f) are cross-sectional views showing diagrammatically a laminated metal electrode manufactured by the first embodiment according to the present invention in order of the manufacturing steps.
FIG. 4 is a characteristic diagram showing the relationship between the number of Ar atoms per unit area and Ti-Si peel-off area ratio.
FIG. 5 is a model diagram showing the peeling mechanism of a Ti-Si interface.
FIGS. 6(a) and 6(f) are cross-sectional views showing a laminated metal electrode manufactured according to the second embodiment of the present invention in order of the manufacturing steps.
FIG. 7 is a diagram showing the thickness of an amorphous Si layer existing in the surface of a silicon substrate before and after an Ar reverse sputtering process.
FIG. 8 is a characteristic diagram showing the relationships between substrate temperature and Ti-Si peel-off area ratio.
FIG. 9 is a diagram explaining the junction mechanism of a Si-Ti interface.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
FIG. 1 is a vertical cross-sectional view showing a semiconductor device (DMOS element) manufactured by applying the first embodiment according to the present invention. The present embodiment will be explained below in conjunction with the manufacturing steps shown in FIG. 3. FIGS. 3(a) to 3(f) show diagrammatically and sequentially the step flows for manufacturing a laminated metal electrode according to the present embodiment.
In FIG. 3(a), the predetermined gate and source regions (not shown) for a power MOS transistor, for example, are formed in a 5-inch diameter, 600 μm thick silicon (Si) substrate. Then, as shown in FIG. 3(b), an aluminum line 3 acting as a surface electrode is formed in a predetermined pattern. Next, as shown in FIG. 3(c), for example, a nitride silicon (SiN) layer 5 acting as a passivation film, is formed using plasma CVD process to protect the aluminum line 3.
After element components have been formed on the surface side of the silicon substrate 1, the silicon substrate 1 is transferred to the sputtering system as shown in FIG. 2 to form a metal film working as the drain electrode of a MOS transistor on the back surface of the silicon substrate 1. The sputtering system shown in FIG. 2 is the XM-8 model, DC parallel plate magnetron sputtering system made by Varian Co. In this embodiment, the sputtering is performed under the conditions that the substrate temperature is about 20° C. and the pressure of argon (Ar) gas 21 introduced in the chamber 23 is 7.5 mTorr. The argon gas is introduced into the chamber 23 from the gas inlet 53 through the massflow meter 51. The argon pressure depends on the amount of argon supplied through the massflow meter as well as the vacuum degree achieved by a vacuum pump described later. In FIG. 2, the vacuum pump system comprises a rotary pump 55, a turbo pump 57, and a cryopump 59. In the vacuuming process, the rotary pump 55 conducts a rough evacuation, the turbo pump 57 conducts an intermediate evacuation and an evacuation of the lock chamber 61, and the cryopump 59 conducts a final evacuation.
In FIG. 2, first, the transferring lock table 27 receive a wafer from the transport 25, and in turn descends to transfer it to a shuttle (not shown). The shuttle is constructed so as to move along the broken line shown in FIG. 2, and first moves the received wafer onto the process table 29. In the station (etching chamber) 13, a RF power source is connected so as to apply the lower potential to the process table 29 and the higher potential (or ground potential) to the capture 31. In this embodiment, the sputtering is performed at a low output of 15 W for a short period of 90 seconds. The ionized Ar gas bombards the back surface of the silicon substrate 1, and etches the top surface of the back side by about 2.5 nm. The etching removes the natural oxide film of about 2 nm grown on the top surface as well as a contaminant such as carbon. The argon gas bombardment also converts the top surface of the silicon substrate into an amorphous. In the above sputtering condition, the amount of argon atoms existing in the amorphous Si layer was 2.0×10 14 atoms/cm 2 . The capture 31 is used to collect contaminants (natural oxide film and the like) on the silicon surface. In FIG. 2, numeral 33 represents a magnet for enclosing electrical discharge.
Next, a wafer is transferred in the station (Ti film forming chamber) 15 using the shuttle, and then placed on the process table 35. In the station 15, a DC power source is connected so as to apply the higher potential (or ground potential) to the process table 35 and the lower potential to the target 37 containing titanium (Ti). In this state, a sputtering is performed under the condition of the output of 2 kW for 75 seconds. The ionized argon gas bombards the target 37 and Ti atoms sputtered out of the target 37 are deposited on the silicon substrate 1 to form a Ti film 7 of a thickness of about 250 nm. On the way of the deposition process, an Si-Ti amorphous layer 8 is formed in the interface between the silicon substrate 1 and the Ti film 7, as shown in FIG. 3(d). In FIG. 3(d), numeral 6 represents an amorphous Si layer containing Ar atoms.
Next, the wafer is transferred into the station (Ni film forming chamber) 17 using the shuttle and then arranged it on the process table 39. In the similar manner to that performed at the station 15, a DC power source in the station 17 is connected so as to apply the higher potential to the process table 39 and the lower potential to the target 41 containing nickel (Ni). In this state, Ar gas ionized by sputtering at an output of 1 kW for 240 seconds bombards the target 41. The Ni atoms sputtered out of the target 41 are deposited on the Ti film 7 to form a Ni film 9 having a thickness of about 600 nm, as shown in FIG. 3(e).
The wafer is transferred to the station (Au film forming chamber) 19 using the shuttle and then arranged on the process table 43. In the station 19, a DC power source is connected so as to apply the higher potential to the process table 43 and the lower potential to the target 45 containing gold (Au). In this state, Au atoms are deposited on the Ni film 9 by sputtering at the output of 0.5 kW for 12 seconds to form an Au film 11 of about 50 nm thick, as shown in FIG. 3(f).
In such a manner, the wafer on which Ti, Ni, Au are deposited sequentially to form a back electrode on the back surface is sent to the transfer lock table using the shuttle, and is send to the transport 49 through the lifting operation of the transfer lock table. Thereafter, the semiconductor device is manufactured as shown in FIG. 1.
In the above explanation, the detailed structure of the power MOS transistor has been omitted. The structure may be applied for bipolar elements, diodes and the like, in addition to the well-known MOS structures.
Next, an explanation will be made as for the mechanism of the adhesion between Si and Ti in the structure shown in FIG. 1 manufactured according to the above manufacturing process.
FIG. 4 shows the relationships between the number of argon atoms per unit area, existing in a Si substrate during an argon etching which is performed prior to the Ti film deposition in the step shown in FIG. 3(d), and the results of peeling-off test which is done to the back electrode of Ti, Ni, Au formed actually. As well-known, the peeling-off test is a method of pasting an adhesive tape on the back of a 5 mm square chip (adhesion strength of about 80 N/m) and then examining the state of the chip from which the adhesion tape is peeled off.
As obvious from FIG. 4, there is a relationship between the amount of remaining argon atoms per unit area and the Si-Ti peeling. When the number of argon atoms per unit area is less than about 4.0×10 14 atoms/cm 2 the Si-Ti is not peeled off because of the strong adhesiveness. However, when the number of argon atoms exceeds about 4.0×10 14 atoms/cm 2 the peeling occurs FIG. 4 shows the results in the case of the substrate temperature of 20° C. The same result as that seen in FIG. 4 was obtained even by forming the electrode at the substrate temperature of about 350° C. It was been confirmed the fact that the peeling between Si and ti does not occur when the number of argon atoms per unit area is less than about 4.0×10 14 atoms/cm 2 .
That reason is considered that, as shown in the peeling model diagram of FIG. 5, the silicon atoms in the substrate surface diffuse easily into a Ti film during the Ti film deposition, but the argon atoms diffused into the substrate during the reverse sputtering process do not diffuse and concentrate in the interface between a Si-Ti diffusion layer and a Si substrate, so that the argon atoms concentrated in the interface which does not contribute the bonding between Si and Ti deteriorates the adhesion strength, thus causing peeling. The amount of argon atoms in the range where the peeling does not occur with respect to the stress of a Ni film exists. When the number of argon atoms per unit area, existing in the silicon substrate, is less than about 4.0×10 14 atoms/cm 2 , a strong adhesion strength can be obtained because of the small amount of argon atoms. However, when the number of Ar atoms exceeds the above mentioned value, it is considered that the peeling-off occurs due to the Ar concentration at the interface. As described later, when the substrate temperature is over about 350° C., argon can be diffused. However it is desirable that the number of Ar atoms existing in the interface covers the above mentioned range.
This mechanism can be supported by performing micro-analysis of peeled surfaces.
Table 1 shows the results obtained by analyzing the peeled surfaces of Si/Ti layer which is formed at a substrate temperature of 20° C. and has the argon atom amount of 6.0×10 14 atoms/cm 2 remaining in the silicon substrate, using X-ray Photoelectron Spectroscopy.
TABLE 1______________________________________ Si(2P) Ti(2P) Ar(2P) O(1S) C(iS)______________________________________Analytical Intensity 1.00 8.20 <0.01 7.40 1.19of Ti SideAnalytical Intensity 1.00 0.02 0.07 1.05 0.06of Si Side______________________________________
(The results were evaluated mutually with respect to the peak intensity of Si(2P) as a reference.)
As seen from Table 1, Ar, Si, C, and O are detected from the Si side, while Ti, Si, C, and O are detected from the Ti side. It can be confirmed that the fact that Ar atoms are not detected at the Ti side means that they cannot be diffused into Ti layer. In this case, it is considered that C and O detected are contents in the air absorbed during the analysis.
As described above, according to the above first embodiment, when the top surface of a substrate is cleaned by performing an Ar reverse sputtering prior to the deposition of the Ti film 7, the number of argon atoms per unit area introduced into the silicon substrate is adjusted to less than 4.0×10 14 atoms/cm 2 , that is, 2.0×10 14 atoms/cm 2 by controlling the sputtering condition. Hence even if Ar atoms which does not contribute to the bonding of the Si/Ti interface concentrates during the deposition of the Ti film 7, a strong bonding can be maintained by the Si-Ti amorphous layer 8 without affecting the Si-Ti bonding, whereby the bonding between Si and Ti can be made strong sufficiently with respect to the film stress of the Ni film 9.
In this case, it is not necessary not only to make the substrate with special rough back surface, but also to increase the number of the steps. Furthermore, since the natural oxide film on the back surface of a substrate is removed using Ar reverse sputtering without etching with HF-based etchant, it is possible to remove contamination due to organic material such as carbon without requiring an increased number of steps and a large sized manufacturing apparatus. The adhesion strength obtained at the Si-Ti amorphous layer does not require any annealing step for improving adhesion strength after the formation of a Ti/Ni/Au film. As a result, it is possible to prevent an increased number of steps because of additional thermal processing, Au spiking of Ni, and solder wetting failure caused by diffusion and oxidation to the top surface. In addition, it Can be prevented that the thermal processing causes a degraded adhesion strength due to the alloy layer with many voids formed between Ti film and Ni film as well as a large warp of wafer. Still furthermore, since a strong bonding can be achieved even at a lower substrate temperature of, for example, 20° C. during a formation of an electrode on the back surface, the aluminum electrode line formed on the surface of a silicon substrate is not deteriorated thermally.
Second Embodiment
Next, the second present embodiment will be explained according to the manufacturing steps referring to FIG. 6. FIGS. 6(a) to 6(f) show diagrammatically a laminated metal electrode formed according to the present embodiment in the order of the manufacturing steps. Like numerals are provided to the same elements as those seen in the first embodiment.
First, referring FIG. 6(a), in the same manner as in the first embodiment, after the predetermined source and drain regions (not shown) for a power MOS transistor are formed in a silicon (Si) substrate 1 of, for example, 5 inch in diameter and 600 μm in thickness, an aluminum line 3 acting as a surface electrode is formed in a predetermined pattern, as shown in FIG. 6(b). Next, as shown in FIG. 6(c), for example, a nitride silicon (SiN), acting as a passivation film is formed using plasma CVD process to protect the aluminum line 3.
In such a manner after, the element components have been formed on the surface side of the silicon substrate 1, the silicon substrate is transferred to the sputtering system as shown in FIG. 2 to form a metal film for the drain electrode of the MOS transistor on the back surface of the silicon substrate 1. In this embodiment, the pressure of the argon (Ar) gas 21 supplied into the chamber 23 is 5 mTorr.
First, the sputtering condition differs from that of the first embodiment. In the station (etching chamber) 13, the sputtering is carried out under the condition that an output for stable electric discharge is 70 W and a sputtering time is 180 seconds. The ionized argon (Ar+) gas bombards the back surface of the silicon substrate 1 and etches the back surface by about 180Å. The etching removes the natural oxide film grown on the back surface and contamination by carbon or other element. In this time, as shown in FIG. 7, amorphous Si layer due to a damage from the etching exists in the back surface of the substrate.
Next, the substrate 1 is heated at a substrate temperature of 300° C. to 500° C., for example, 400° C., in the station (Ti film forming chamber) 15 which is equipped with a heater (not shown). A Ti film 7 of about 250 nm thick is formed on the silicon substrate 1 by sputtering under the condition of at 2 kW for 75 seconds which is the same as that in the first embodiment. On the way of the deposition, the Ar atoms implanted into the silicon substrate are diffused by the substrate heating process using the heater and, the above mentioned damage layer or the amorphous Si layer disappears. As a result, as shown in FIG. 6(d), the Si-Ti amorphous layer 8 is formed at the interface between the silicon substrate 1 and the Ti film 7.
Next, in the same manner as that in the first embodiment, a sputtering is performed at 1 kW for 240 seconds in the station (Ni film forming chamber) 17 to form a Ni film 9 with a thickness of about 600 nm as shown in FIG. 6(e).
Furthermore, in the same manner as that in the first embodiment, a sputtering is carried out at 0.5 kW for 12 seconds in the station (Au film forming chamber) 19 to form an Au film 11 with a thickness of about 50 nm on the Ni film 9, whereby a semiconductor device shown in FIG. 1 is made as shown in FIG. 6(f).
Next, an explanation will be made as for the mechanism of the adhesion between Si layer and Ti layer in the present second embodiment.
FIG. 8 shows the relationship between the substrate temperature determined by means of a heater for Ti film deposition during the step shown in FIG. 6(d), and the results of the peeling-off test to the back electrode of Ti, Ni, and Au formed actually. The reverse sputtering is carried out under the condition for the step shown in FIG. 6(d). FIG. 8 also shows the result of the peeling-off test where the substrate back etching using Ar reverse sputtering was not performed prior to the Ti film deposition.
As seen clear from FIG. 8, in case where the back surface of a substrate is cleaned through a reverse sputtering, while it is converted into an amorphous and a Ti film is deposited at a substrate temperature of 300° C. or more, no peeling between Si layer and Ti layer occurs, but strong bonding can be obtained. However, when either no reverse sputtering or a reverse sputtering performed at the substrate temperature of less than 300° C. without controlling the output thereof like the first embodiment is carried out, a peeling occurs.
In the case of no argon reverse sputtering, since the top surface of the silicon substrate 1 is SiO 2 , as shown in FIG. 9(a), it does not react with the Ti film 7, whereby a film peeling occurs. On the other hand, in case where an Ar sputtering is performed, the natural oxide film SiO 2 groom on the top surface of the silicon substrate 1 is removed but the top surface thereof is damaged. As explained regarding the first embodiment in conjunction with FIG. 5, the top surface is converted into an amorphous Si. The Si/Ti interface does not make in nature a titanium siliside with a strong bond at a temperature of less than 550° C. However, since the amorphous Si layer being a layer damaged by the reverse sputtering reacts easily with Ti, a strong bonding layer or a Si-Ti amorphous layer 8 can be formed easily even at a lower temperature. In the first embodiment, the reverse sputtering is determined on condition that the amount of Ar atoms at the electrode/Si interface is less than 4.0×10 14 atoms/cm 2 . But in the case where a special measure for the argon revere sputtering is not taken, as shown in the present embodiment, it is considered that argon atoms which concentrates at the interface between Si and Si/Ti amorphous layer diffuses easily into the Ti film when the substrate temperature is more than 300° C. As a result, as shown in FIG. 9(c), it is considered that the strong adhesiveness does not cause a film peeling. However, as explained regarding the first embodiment referring to FIG. 5, it is considered that since the substrate temperature is less than 300° C., the presence of the amorphous Si layer or Ar atoms in the amorphous Si layer decreases the strength, a film peeling occurs, as shown in FIG. 9(b).
As described above, according to the second embodiment, the back surface electrode is formed at a substrate of 300° C. to 500° C. after the top surface of a substrate is cleaned using Ar reverse sputtering prior to a deposition of the Ti film 7. Hence in a Ti deposition process to the silicon substrate 1, since Ti reacts easily with the amorphous Si layer existing in the top surface of a Si substrate, an amorphous layer of Si-Ti is formed, while the Ar atoms existing in amorphous Si layer are distributed through diffusion. As a result, the number of Ar atoms which remain in the interface between the Si substrate and the contact metal film is less than 4.0×10 14 atoms/cm 2 and the junction between-Si layer and Ti layer can be made strong sufficiently with respect to the film stress of the Ni film 9, in no relation with the absolute amount of Ar introduced into the Si substrate. In this case, since the substrate temperature during Ti deposition is less than 500° C., the heat deterioration of an aluminum electrode formed on the surface of a silicon substrate does not occur.
In the first and second embodiments of the Ti layer 7 is formed as an example to make an ohmic contact with the surface of a wafer. However, instead of Ti, for example, chrome (Cr), vanadium (V), zirconium (Zr), aluminum (Al), or gold (Au) may be formed for an ohmic contact. The thickness of Ti film can be 100 nm to 400 nm, without being limited to 250 nm. The thickness of the Ni layer can be 200 nm to 1000 nm, without being limited to 600 nm.
The first and second embodiments show that not only Ti film 7 but also Ni film 9 and Au film 11 are formed at the same substrate temperature as that for a deposition of the Ti film 7. However, as disclosed on the Japanese Patent Laid-Open No. 167890-1990, it is considered that the effect of the present invention is improved further if the film stress of a Ni film is made less than 3×10 8 N/m 2 by controlling accurately the substrate temperature to 100° C. to 250° C. and the Ar pressure during a Ni film formation to more than 12 mTorr.
Furthermore, in the substrate cleaning process by Ar reverse sputtering, the number of Ar atoms existing in the Si substrate may be less than 4.0×10 14 atoms/cm 2 as shown in the first embodiment and the substrate temperature may be determined more than about 300° C. only during Ti film formation as shown in the second embodiment. Furthermore, as disclosed in the laid-open Japanese Patent Application Laid-Open No. 167890-1990, a Ni film may be formed on the structure obtained above. | A method for forming electrodes with strong adhesion strength for a semiconductor device is provided. The adhesion strength between a Si substrate and a Ti film is made higher than the pulling stress of a Ni film. Before an electrode is formed using sputtering process, the natural oxide film grown on a semiconductor substrate is removed using an Ar reverse sputtering while the top surface of the silicon substrate is converted to an amorphous through a bombardment and introduction of Ar. While Ti is deposited, a Si-Ti amorphous layer is formed in the Si/Ti interface. In this case, the amount of Ar atoms is controlled less than 4.0×10 14 atoms/cm 2 . The Ar amount also can be controlled by adjusting the conditions such as the output or cathodic voltage of Ar reverse sputtering and decreasing the absolute value of Ar in the amorphous Si layer. Also the Ar amount can be controlled by diffusing Ar atoms into the substrate at more than about 300° C. during Ti film deposition to diverse the Ar distribution. As a result argon atoms which concentrates at the interface do not affect with respect to the Si-Ti amorphous layer, whereby the bonding strength of the amorphous layer is maintained. Therefore, the strong adhesion strength between Si and Ti can provide a sufficient durability against the film stress of the Ni film. | 8 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates in general to a system for sampling gas and, in particular, is directed to a system for sampling a gas containing a reactive particulate solid phase such that essentially all of the solids are removed in such a manner that the gas phase composition is essentially unchanged. Thus, a representative gas sample is obtained for determining its composition by a gas analyzer.
2. DESCRIPTION OF THE RELATED ART
Gas sampling systems are available from several vendors such as E. I. DuPont, etc., for use with gas analyzers. These systems, when designed for dust-laden gases, clean the gas by filtration through a mesh screen or porous media. Where chemical reactions between the gas and particulate matter potentially exist, these systems inadvertently allow these chemical reactions to alter the chemical composition of the gas sample by providing an intimate contact zone. Thus, the gas analysis equipment measures gas concentrations unrepresentative of the bulk gas stream.
Flue gas from fossil fuel fired boilers is one example of this kind of gas-solid mixture. Recent concerns and awareness in our environment have led to new efforts to refine our boiler technology with the removal and/or reduction of air pollutants such as particulates, sulfur oxides (SO x ), and oxides of nitrogen (NO x ).
During the combustion of fossil fuel, various combustion off-gases are produced which contain a variety of contaminants such as sulfur dioxide, sulfur trioxide, and fly ash. U.S. Pat. No. 4,452,765, which is assigned to the assignee of the present invention, discloses a method for removing sulfur oxides from a hot flue gas by introducing an alkali slurry. This patent is hereby incorporated by reference. The present invention finds particular utility in sampling the gas stream at various points in that system to maintain air pollution emission control standards.
Accurate monitoring of the flue gas is required to be sure that methods like this or newly developed ones are effective so that as a minimum they improve the quality of the emission. A representative sample of the gas is necessary for an accurate analysis.
The prior art has recognized some of the problems of analyzing dust-laden gas samples. U.S. Pat. No. 4,485,684 issued to Weber, et al discloses an apparatus for extracting and analyzing dust-laden gas samples. The device employs a stilling chamber tapered downwards in the shape of a horizontal half-funnel in the direction of the flow of the gas. Flanges connect the stilling chamber to a gas sample extraction pipe or sample probe from an exhaust gas line. The gas sample extraction probe of conventional construction extends coaxially in the connecting pipe. A conveying pipe which is connected to a three-way valve acts as a switching valve and connects the gas probe to a conventional filter. From the filter the gas sample goes through a gas feed pump to a gas analyzer. A time control device connected to the three-way valve permits cleaning with compressed air at specific intervals.
A different approach to this problem was used in U.S. Pat. No. 3,106,843, issued to Luxl. This reference discloses an atmosphere sampling probe for gas analyzers to obtain continuous flow of the sample stream. The clogging of the probe during extended periods of operation is prevented by utilizing steam which condenses about the solid particles in the sample stream. Water is supplied to separate the steam by condensing it as well as washing the gas sample of corrosive materials.
Both of these references only address the problem of the filters clogging or plugging with dust. None of these prior art systems recognize the problem that chemical reactions occur between the gas and the particulate material. Nor is the prior art directed to a gas sampling system for sampling a gas containing a reactive solid phase such that the majority of the solids are removed in such a fashion that the gas phase composition is essentially unchanged and is thereby representative of the gas sampled at the initial sampling point.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method for sampling a gas containing a reactive solid phase flowing through a duct and for communicating a representative sample to a gas analyzer. The apparatus comprises a sample probe sheath extending vertically into the top of a gas duct. The sample probe sheath has an angular opening at one end with the opening extending in the opposite direction of the gas flow. A gas sampling probe partially extends into the sample probe sheath. A calibration probe connected to a calibration gas line extends into the sample probe sheath with the calibration probe extending further in the sample probe sheath than the gas sampling probe. At least one filter is connected between the gas sampling probe and a gas analyzer.
The calibration probe extends further in the sample probe sheath than the gas sampling probe for purging the sample probe sheath with the calibration gas during calibration. Both the calibration and gas sampling probes are sealed at the closed end of the sample probe sheath. The apparatus includes a means for maintaining the temperature range which surrounds the apparatus to minimize gas-solids reactions.
Another aspect of the present invention is directed to a method for sampling a gas containing a reactive solid phase and flowing through a duct to communicate a representative sample to a gas analyzer. The method includes the steps of aspirating a gas containing a reactive particulate solid phase into a primary separation zone in a sample probe sheath, and drawing a sample into a sample probe located within the sample probe sheath. Maintaining the temperature within a range which minimizes gas-solids reactions provides for the continuous representative monitoring of the gas concentration. Periodic calibration of the gas analyzer is provided by the calibration probe which discharges a predetermined concentration of gas constituents into the sample probe sheath at a flow rate in excess of the gas sampling rate.
Advantageously, the gas sampling configuration of the present invention allows continuous, representative monitoring of gas concentrations and eliminates damage or drift to instrumentation from solids. Easy access to the filter assembly minimizes downtime when filter changes are required.
The various features of novelty characterized in 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, and the operating advantages obtained by its use, reference is made to the accompanying drawings and descriptive matter in which the preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWING
In the drawings:
FIG. 1 is a schematic block diagram of a portion of a representative boiler system where the present invention is employed to monitor flue gas emission, and
FIG. 2 is a cross-sectional illustration of the preferred embodiment of the present invention in place on a gas duct.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is illustrated a schematic representation of the air pollution control components in a conventional boiler system. Hot flue gas derived from the combustion of fossil fuel is conveyed from a combustion zone, not shown but well known in the art, through conduit 2 to spray drying reactor chamber 4. Steam or air supplied by a source not shown is conveyed by conduit 6 to spray drying reactor chamber 4. The alkali slurry supplied by a system disclosed in U.S. Pat. No. 4,452,765 is delivered to spray drying reactor chamber 4 by means of conduit 8.
The hot flue gas is treated in the fashion as described in U.S. Pat. No. 4,452,765. Settleable particulate matter is removed by gravity for collection in ash hopper 10 where it is conveyed by conduit 12 for ultimate disposal.
The flue gas exits the spray drying reactor chamber 4 passing through a gas reheat zone 14 for gas reheat when required for corrosion control in dry particle collection zone 16. The dry particle collection is achieved with the use of an electrostatic precipitator, a fabric filter, or the like. The treated gas leaves the dry particle collection zone 16 through conduit 18 substantially free of particulate matter and sulfur oxides. The flue gas is then pumped through conduit 20 to an exhaust stack 22 for atmospheric discharge.
Reacted alkali particles and fly ash that are collected in ash hoppers 24 are conveyed by conduit 26 to reprocessing zone 28 for reprocessing and recycling.
Monitoring the flue gas such as in the gas reheat zone 14, and conduits 18, 20 at several points in the system reveals the effectiveness of the pollution control technique. For purpose of this invention, the term "duct or gas duct" is meant to include the above-mentioned points in a boiler system.
With reference to FIG. 2, a gas-solid mixture normally travels through a gas duct 30 with the arrow in duct 30 indicating the direction of flow of the gas-solid mixture. A sample probe sheath 32 extends into the sample gas duct 30. The sample probe sheath has an angular opening 34 at one end with the opening 34 being in the opposite direction of the gas flow as shown by the arrow in gas duct 30. An opening with a 45° angle is preferred. Other angles are usable with probably no significant consequence. A 45° angle is easy to cut, i.e., it is a mitered corner. Alternate geometries can be envisioned such as a closed pipe with a slot opening on the downstream side. However, the angled cut is preferred for cleaning purposes.
The vertically orientated sample probe sheath 32 has a sufficient inner diameter to allow for a primary separation of the particulate solids which accompany the gas sample. In a pilot test, a diameter of 21/2 inches was suitable for a 12 inch gas duct. In the boiler industry, ducts of varying size are encountered and so the emphasis shifts to compliance with the Environmental Protection Agency continuous emission monitoring standards (CEMS). The sample probe sheath 32 extends into a gas duct 30 to a representative location of the gas stream. The sample probe sheath 32 is completely sealed from possible infiltration of ambient air at its opposite end 38.
A conventional gas sampling probe 36 passes through the sample probe sheath end connection 38. The gas sampling probe draws a partially clean, i.e., reduced particulate concentration of gas-solid mixture from the primary separation zone which is defined as a point between the sample probe sheath inlet 34 and the end of the gas sampling probe 36a. The distance from the end of the gas sampling probe 36a to the sample probe sheath inlet 34 may range conveniently from three to eight sample probe sheath inner diameters, but can be a greater distance if sample response times are not critical to the application. A point midway in the sample probe sheath 32 is preferred.
The calibration probe 40 passes through the sample probe sheath end connection 38 for optional delivery of an appropriate calibration gas. One end of the calibration probe 40 is connected to a source for calibration gas (not shown). The calibration line outlet 42 which has a plurality of small apertures discharges into the primary separation zone. A calibration gas at a sufficient volumetric flow rate to purge this area of the sample probe sheath 32 is injected while a calibration gas is drawn into the gas sample probe 36. The calibration gas flow rate must be greater than the sample gas flow rate to insure that this probe sheath 32 is flooded with calibration gas.
The gas sample probe 36 delivers the gas-solid mixture from the primary separation zone to the filter elements 44 through gas line 46. These filters 44 contain media filters which remove a minimum of 99.99% of the entering solids having a diameter equal to or greater than 0.1 microns.
As shown in FIG. 2, two filters 44 are used in parallel to each other. Originally, this arrangement was intended to use one filter at a time with the other as a spare. When it became necessary to change that filter, the operator would switch flow over to the spare filter by a valving arrangement 44a and then replace the used filter when the spare filter became clogged. Due to the amount of time a filter lasts, it was later found merely convenient to simply operate with both filters in parallel. Any number of filters or filter sizes in a suitable arrangement can be used.
In the preferred embodiment, the filters 44 are Balston® type BH filters Type 37/12. These filters have an inorganic binder and are recommended for sample filtrations above 300° F., to a maximum temperature of 900° F.
The filters 44 including line 46 along with the gas sampling probe 36 and calibration probe 38 and the upper portion of the sample probe sheath 32 are maintained within a temperature range to minimize gas-solids reactions (either above or below the gas flow temperature) by the oven 48. These types of ovens which can maintain a temperature range above or below the flow temperature are well known.
The common filter outlet of gas line 46 as it exits filters 44 is connected to a heated hose or other suitable tube 50 to deliver the filtered gas to a conventional gas analyzer 52.
For most applications, the material contacting the gas are made of some grade of stainless steel.
The gas sampling apparatus described allows continuous, representative monitoring of gas concentrations and eliminates damage or drift to the instrumentation from particulate solids. Easy access to the multiple filter assembly minimizes or eliminates downtime when filter changes or maintenance are required.
The following are some example applications of the gas sampling system of the present invention.
One application of this sampling system involves its use with dry scrubbers. In dry scrubbers an aqueous slurry of calcium hydroxide, Ca(OH) 2 , is sprayed into a hot flue gas (typically, about 300° F.) containing traces of sulfur dioxide, SO 2 . The following reaction ensues within the dry scrubber:
Ca(OH).sub.2 +SO.sub.2 →CaSO.sub.3 ·1/2H.sub.2 +1/2H.sub.2 O (I)
Typically, an excess of slurry is sprayed into the flue gas such that as the flue gas leaves the dry scrubber, moist particles of unreacted calcium hydroxide slurry flow coincident with the flue gas. At this point the flue gas is typically below about 200° F. and the relative humidity is above 10%. In a conventional sampling system, a small portion of the flue gas would be extracted from the flue or duct and would be directed to a filter where the calcium hydroxide solids would be separated from the gas sample. A cake of solids would rapidly accumulate on the filter. The reaction noted above, (I), would continue to occur. Thus, any gas sample passing through the filter would no longer contain a representative concentration of SO 2 . The subject invention circumvents this problem in two ways. First, the method by which the flue gas is extracted, i.e., by requiring the flue gas to flow in reverse direction into the probe sheath causes an inertial separation of flue gas and slurry droplets. This serves to minimize (but not eliminate) the amount of solids which will reach and deposit on the filter. Secondly, experience has shown that the above reaction proceeds at a negligible rate when the relative humidity of the flue gas approaches zero. Therefore, by placing the external filter of this subject invention in a zone where the temperature is maintained between 250° F. and 350° F. this reaction can be minimized. As a result, the SO 2 concentration is not diminished as it passes across a filter cake of dry Ca(OH) 2 .
Another benefit of the subject invention when compared to conventional filter based sampling systems is that frequent filter cleaning by various "blow back" procedures (as is usually used in commercial sampling systems) is not necessary. In-duct filters frequently require blow back every twenty minutes or so in order to prevent pluggage by the filter cake or to prevent significant sample degradation by accumulations of reactive solids. The subject invention minimizes the rate of accumulation of filter cake by the inertial separation step. That factor in combination with the temperature control which minimizes the reactivity of the filter cakes allows operation even in very dirty applications for up to several weeks before filter replacement becomes necessary. An added benefit of this fact is that media type filters can be used in place of sintered ceramic or metal filters which are used with blow back systems. Media filters (usually fiber glass) are much more effective filters and operate generally at much lower pressure drop than do the sintered type filters.
A second example of a system where the subject invention is applicable is in sampling flue gas in furnace sorbent injection applications. Typically, the reaction involved is represented by:
CaO+SO.sub.2 +1/2O.sub.2 →CaSO.sub.4 (II)
This reaction is very rapid in the temperature range from about 1500° F. to about 2300° F. but diminishes to a negligible rate below about 700° F. Therefore, filtration at any temperature below about 700° F. should present no reaction problems via reaction (II). In principle, therefore, in-duct filters used in this temperature range should work adequately. However, because these in-duct filters must by cleaned by blow-back with compressed air, that filter is periodically cooled by the relatively cold compressed air to temperatures well below 700° F. When that happens, moisture can condense on the filter causing the deposits to become moist and therefore reactive via reaction (I). As in example one above, the subject invention avoids these problems by maintaining the filtration step at a temperature of about 300° F. and by avoiding the need for blow-back of the filter.
A third example of a system where this subject invention has been tested is on a wet scrubber utilizing a solution of sodium carbonate to react with SO 2 via:
NaCO.sub.3 +SO.sub.2 →Na.sub.2 SO.sub.3 +CO.sub.2 (III)
The sampling constraints here are similar to the first example. However, the reactivity of sodium carbonate is greater than Ca(OH) 2 and therefore, greater care must be taken in controlling the filtration temperature. By coincidence, 300° F. is the optimum temperature to filter sodium carbonate from the sampled flue gas.
The foregoing examples are intended for illustrative purposes and are not meant to limit the present invention only to these applications. The gas sampling system of the present invention has utility in any system where there exists a gas-solid mixture with the possible occurrence of gas-solid reactions.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of principles of the invention, certain modifications and improvements will occur to those skilled in the art upon reading the foregoing description. It is thus understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly in the scope of the following claims.
One example of such a modification would be to include a plurality of filters in parallel with valves directing the sampled gas to a predetermined filter or set of filters. | An apparatus and method for sampling a gas containing a reactive particulate solid phase flowing through a duct and for communicating a representative sample to a gas analyzer. A sample probe sheath 32 with an angular opening 34 extends vertically into a sample gas duct 30. The angular opening 34 is opposite the gas flow. A gas sampling probe 36 concentrically located within sheath 32 along with calibration probe 40 partly extend in the sheath 32. Calibration probe 40 extends further in the sheath 32 than gas sampling probe 36 for purging the probe sheath area with a calibration gas during calibration. | 6 |
RELATED APPLICATIONS
[0001] The present application is related to co-pending application Ser. No. 10/925,743 filed Aug. 25, 2004, and Ser. No. 10/857,716 filed May 28, 2004, both of which are assigned to the assignee of the present application.
FIELD OF THE INVENTION
[0002] The present invention relates generally to digital computer network technology; more particularly, to methods and apparatus for providing redundancy mechanisms for network connections.
BACKGROUND OF THE INVENTION
[0003] The performance of many applications benefit from being implemented over service provider networks that support multipoint network services. A multipoint network service is one that allows each customer edge (CE) end point or node to communicate directly and independently with all other CE nodes. Ethernet switched campus networks are an example of a multipoint service architecture. The multipoint network service contrasts with more traditional point-to-point services, such as hub-and-spoke network services, where the end customer designates one CE node to the hub that multiplexes multiple point-to-point services over a single User-Network Interface (UNI) to reach multiple “spoke” CE nodes. In a hub-and-spoke network architecture, each spoke can reach any other spoke only by communicating through the hub. Traditional network service offering to the end customers via wide area networks (WANs) such as Frame Relay (FR) and asynchronous transfer mode (ATM) networks are based on a hub-and-spoke service architecture.
[0004] Virtual Private Network (VPN) services provide secure network connections between different locations. A company, for example, can use a VPN to provide secure connections between geographically dispersed sites that need to access the corporate network. There are three types of VPN that are classified by the network layer used to establish the connection between the customer and provider network. Layer 1 VPNs are simple point-to-point protocol (PPP) connections such as leased lines, ISDN links, and dial-up connections. In a Layer 2 VPN (L2VPN) the provider delivers Layer 2 circuits to the customer (one for each site) and provides switching of the customer data. Customers map their Layer 3 routing to the circuit mesh, with customer routes being transparent to the provider. Many traditional L2VPNs are based on Frame Relay or ATM packet technologies. In a Layer 3 VPN (L3VPN) the provider router participates in the customer's Layer 3 routing. That is, the CE routers peer only with attached PEs, advertise their routes to the provider, and the provider router manages the VPN-specific routing tables, as well as distributing routes to remote sites. In a Layer 3 Internet Protocol (IP) VPN, customer sites are connected via IP routers that can communicate privately over a shared backbone as if they are using their own private network. Multi-protocol label switching (MPLS) Border Gateway Protocol (BGP) networks are one type of L3VPN solution. An example of an IP-based Virtual Private Network is disclosed in U.S. Pat. No. 6,693,878. U.S. Pat. No. 6,665,273 describes a MPLS system with a network device for traffic engineering.
[0005] Virtual Private LAN Service (VPLS) is an emerging technology that addresses the need for Layer 2 multipoint VPN that connects multiple sites within a specific metropolitan geographic area. VPLS is an architecture that delivers a Layer 2 multipoint VPN service that in all respects emulates an Ethernet LAN across a wide metropolitan geographic area. All services in a VPLS appear to be on the same LAN, regardless of location. In other words, with VPLS, customers can communicate as if they were connected via a private Ethernet segment, i.e., multipoint Ethernet LAN services. VPLS thus supports the connection of multiple sites in a single bridged domain over a managed IP/MPLS network.
[0006] In typical VPLS architecture with an IP/MPLS service provider (SP) network core, the CE devices are connected to the service provider network via a PE device. (The connection between a CE-PE pair of devices is commonly referred to as a UNI.) Each PE-CE pair is shown connected by an Attachment Circuit (AC). An AC is the customer connection to a service provider network; that is, the connection between a CE and its associated PE. An AC may be a point-to-point connection on a physical interface, a PPP session from an L2TP tunnel, an MPLS Label Switched Path (LSP), or a virtual port, and may be any transport technology, i.e., Frame Relay, ATM, a VLAN, etc. In the context of a VPLS, an AC is typically an Ethernet port, in which Ethernet serves as the framing technology between the CE device and the PE router. CE devices can also be connected through several edge domains, also known as access domains, which are interconnected using an MPLS core network. Such access domains can be built using Ethernet switches and techniques such as VLAN tag stacking (so-called “QinQ” encapsulation). By way of example, each PE device in an access domain typically includes a Virtual Switch Instance (VSI) that emulates an Ethernet bridge (i.e., switch) function in terms of MAC address learning and forwarding in order to facilitate the provision of a multi-point L2VPN. In such networks, pseudowires (PWs) are commonly utilized to connect pairs of VSIs associated with different access domains.
[0007] A PW is a virtual connection between two PE devices which connect two ACs. Conceptually in context of the VPLS service, a PW can be thought of as point-to-point virtual link for each offered service between a pair of VSIs. Therefore, if each VSI can be thought of as a virtual Ethernet switch for a given customer service instance, then each PW can be thought of as a virtual link connecting these virtual switches over a Packet Switched Network (PSN) to each other for that service instance. During setup of a PW, the two connecting PE devices exchange information about the service to be emulated in order to be able to properly process packets received from the other end in the future.
[0008] Another type of provider provisioned VPN architecture that uses PWs is the Virtual Private Wire Service (VPWS). VPWS is a Layer 2 service that provides point-to-point connectivity (e.g., Frame Relay, ATM, point-to-point Ethernet) and can be used to create port-based or VLAN-based Ethernet private lines across a MPLS-enabled IP network. Conceptually, in the context of the VPWS service, a PW can be thought of as a point-to-point virtual link connecting two customer ACs. After a PW is setup between a pair of PEs, frames received by one PE from an AC are encapsulated and sent over the PW to the remote PE, where native frames are reconstructed and forwarded to the other CE. PEs in the SP network are typically connected together with a set of tunnels, with each tunnel carrying multiple PWs. The number of PWs setup for a given customer can vary depending on the number of customer sites and the topology for connecting these sites.
[0009] Similar to Ethernet switches, VPLS-capable PE devices are capable of dynamically learning the Media Access Control (MAC) addresses (on both physical ports and virtual circuits) of the frame packets they replicate and forward across both physical ports and PWs. That is, each PE device is capable of learning remote MAC addresses-to-PW associations and also learns directly attached MAC addresses on customer facing ports. To achieve this result, PE devices maintain a Forwarding Information Base (FIB) table for each VPN and forward frames based on MAC address associations. Another attribute of an Ethernet network is that frames with unknown destination MAC addresses are flooded to all ports.
[0010] For an Ethernet network to function properly, only one available path can exist between any two nodes. To provide path redundancy and prevent undesirable loops in the network domain topology caused by multiple available paths, Ethernet networks typically employ Spanning Tree Protocol (STP), or some variant of STP, e.g., MSTP or RSTP. (For purposes of the present application, STP and its variants are generically denoted by the acronym “xSTP”.) Switches in a network running STP gather information about other switches in the network through an exchange of data messages called Bridge Protocol Data Units (BPDUs). BPDUs contain information about the transmitting switch and its ports, including its switch and port Media Access Control (MAC) addresses and priorities. The exchange of BPDU messages results in the election of a root bridge on the network, and computation of the best path from each switch to the root switch. To provide path redundancy, STP defines a tree from the root that spans all of the switches in the network, with certain redundant paths being forced into a standby (i.e., blocked) state. If a particular network segment becomes unreachable the STP algorithm reconfigures the tree topology and re-establishes the link by activating an appropriate standby path. Examples of networks that run STP are disclosed in U.S. Pat. Nos. 6,519,231, 6,188,694 and 6,304,575.
[0011] A particular redundancy problem arises when Ethernet and STP are combined with pseudowires. Basically, when there are two or more pseudowires connecting different Ethernet access domains that independently run STP, broadcast and multicast packets can be replicated, and packets can be “looped back” across the core network through the pseudowires. The source of this problem is twofold: On one hand, STP is designed to build a path with no loops by disabling (i.e., blocking) any links which could forward traffic to the same destination. On the other hand, VPLS and Ethernet Relay Service (ERS) applications, which use VLAN tags to multiplex several non-same-destination pseudowires to a single port, assume that a full mesh of PWs connecting all involved PEs is the most efficient network topology. (Loops are dealt with in VPLS and ERS via a mechanism known as “split-horizon”.)
[0012] One possible solution to this problem is to devise a mechanism for running STP over pseudowires; however, this approach is considered too unwieldy and difficult to implement. Another proposed architectural solution is to utilize only a single PW that connects different Ethernet access domains across the core network. The primary drawback of this latter approach is that it means that it installs a single point of failure in network connections. In other words, if the PW connection fails or if the associated PE devices in the access networks fail, end-to-end connectivity is defeated.
[0013] Thus, there is an unsatisfied need for alternative network architectures and topologies that overcomes the shortcomings of the prior art.
[0014] By way of further background, U.S. Pat. No. 6,073,176 discloses a multi-chassis, multi-link point-to-point protocol (PPP) that uses Stack Group Bidding Protocol (SGBP) to conduct multi-link PPP sessions for links that either originate or terminate on different systems. Historically, SGBP has been used for dial-up customer (UNI) facing interfaces to allow network servers to be stacked together and appear as a single server, so that if one server fails or runs out of resources, another server in the stack can accept calls. For instance, U.S. Pat. No. 6,373,838 teaches a dial-up access stacking architecture (DASA) with SGBP that implements a large multi-link dial port in which multiple communication links from one site are established to stack group members that operate together as a multi-link bundle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will be understood more fully from the detailed description that follows and from the accompanying drawings, which however, should not be taken to limit the invention to the specific embodiments shown, but are for explanation and understanding only.
[0016] FIG. 1 illustrates one aspect of an exemplary VPLS system with an IP/MPLS core network and separate access network domains in accordance with one embodiment of the present invention.
[0017] FIG. 2 illustrates another aspect of an exemplary VPLS system with an IP/MPLS core network and separate access network domains in accordance with one embodiment of the present invention.
[0018] FIG. 3 is a flow chart diagram showing a method of operation in accordance with one embodiment of the present invention.
[0019] FIG. 4 is a generalized circuit schematic block diagram of a network node.
DETAILED DESCRIPTION
[0020] A network architecture that provides redundant pseudowires between Ethernet access domains without replicated broadcast and multicast packets, “loopbacks”, or a single point of failure is described. In the following description specific details are set forth, such as device types, protocols, configurations, etc., in order to provide a thorough understanding of the present invention. However, persons having ordinary skill in the networking arts will appreciate that these specific details may not be needed to practice the present invention. Practitioners in the network arts will further appreciate that the architecture of the present invention is useful for Ethernet Wire Service (EWS) applications, which emulate point-to-point Ethernet segments, as well as Ethernet Relay Service (ERS) applications, which use VLAN tags to multiplex several non-same-destination pseudowires to a single port.
[0021] A computer network is a geographically distributed collection of interconnected subnetworks for transporting data between nodes, such as intermediate nodes and end nodes. A local area network (LAN) is an example of such a subnetwork; a plurality of LANs may be further interconnected by an intermediate network node, such as a router or switch, to extend the effective “size” of the computer network and increase the number of communicating nodes. A wide area network (WAN) is a data communications network that spans any distance. Examples of the end nodes may include servers and personal computers. The nodes typically communicate by exchanging discrete frames or packets of data according to predefined protocols. In this context, a protocol consists of a set of rules defining how the nodes interact with each other.
[0022] As shown in FIG. 4 , each node 70 typically comprises a number of basic subsystems including a processor subsystem 71 , a main memory 72 and an input/output (I/O) subsystem 75 . Data is transferred between main memory (“system memory”) 72 and processor subsystem 71 over a memory bus 73 , and between the processor and I/O subsystems over a system bus 76 . Examples of the system bus may include the conventional lightning data transport (or hyper transport) bus and the conventional peripheral component [computer] interconnect (PCI) bus. Node 70 may also comprise other hardware units/modules 74 coupled to system bus 76 for performing additional functions. Processor subsystem 71 may comprise one or more processors and a controller device that incorporates a set of functions including a system memory controller, support for one or more system buses and direct memory access (DMA) engines. In general, the single-chip device is designed for general-purpose use and is not optimized for networking applications.
[0023] In a typical networking application, packets are received from a framer, such as an Ethernet media access control (MAC) controller, of the I/O subsystem attached to the system bus. A DMA engine in the MAC controller is provided a list of addresses (e.g., in the form of a descriptor ring in a system memory) for buffers it may access in the system memory. As each packet is received at the MAC controller, the DMA engine obtains ownership of (“masters”) the system bus to access a next descriptor ring to obtain a next buffer address in the system memory at which it may, e.g., store (“write”) data contained in the packet. The DMA engine may need to issue many write operations over the system bus to transfer all of the packet data.
[0024] According to one aspect of the present invention, a network topology is provided in which WAN traffic flows on a single pseudowire between nodes (e.g., PE devices such as routers or switches) associated with different access domains for a specific VLAN. Rather than a full mesh of PWs spanning across the SP core network, only one path across the core network exists per VLAN. In the event of a failure of the PW connection, e.g., one of the PE devices fails, or if the primary WAN router changes, an alternative PW is activated as a redundant path.
[0025] In accordance with one embodiment of the present invention, activation of a redundant PW path is achieved by having multiple PE devices in each access domain, with the PE devices being grouped in a stack. A protocol similar to SGBP (“SGBP-like”) runs on one or more processors of the PE devices in each group such that each PE device is aware of which device in the group operates as a primary or backup connection device for any particular link. In the context of the present application, a stack group is defined as a collection of two or more nodes or devices configured to operate as a group in an Ethernet access network. The devices in the stack group support a single PW connection across a core network to another stack group associated with a different Ethernet access network.
[0026] FIG. 1 illustrates a basic network topology according to one embodiment of the present invention which includes independent Ethernet access domains 20 & 30 connected via a single path across a SP IP/MPLS core network 11 . In this example the path across the core is shown by a single PW 44 that connects core network-facing provider edge (n-PE) devices 24 & 33 , which are respectively associated with stack groups 25 & 35 of access domains 20 & 30 . Each stack group 25 & 35 is shown including a second, redundant n-PE device 23 & 33 , respectively, although there is no limit on the number of n-PE devices that may be included in a stack group. Devices 23 & 24 and 33 & 34 are typically edge routers or switches capable of running a protocol to set up PW connections. The n-PE devices 23 & 24 of access domain 20 are connected with a user-facing provider edge (u-PE) device 22 , which, in turn, connects with a CE device 21 . On the other side of core network 11 , n-PE devices 34 & 35 of access domain 30 are connected with u-PE device 32 , which is connected with CE device 31 .
[0027] The basic idea of the present invention is to allow multiple originating end n-PE devices of a stack group in an access domain to bid for the right to create a unidirectional Ethernet pseudowire connection across the core network. A similar bidding process allows for a return pseudowire connection to be created. In other words, a single stack group of potentially distributed nodes manages external connectivity. Bidding among nodes occurs independently in each stack group located on opposite sides of the core network, with a single connection path being established across the core between n-PE devices in their respective access domain. The use of a SGBP-like protocol running in the stack groups (represented in FIG. 1 by dashed lines 26 and 36 ) of the respective access domains insures redundancy in the event of a connection failure, as explained in more detail below.
[0028] In the example of FIG. 1 , a bidding process within stack group 35 results in the selection of n-PE device 33 for sending a connection request out across the core network. The connection request, shown by arrow 41 , is received by n-PE device 24 of stack group 25 . Device 24 responds to the request by initiating a bidding process in stack group 25 to determine which n-PE device (i.e., as between devices 23 & 24 ) should create the tunnel connection across the core. After the bidding process in stack group 25 has finished, a response that indicates where the tunnel is to be established is sent back to access domain 33 . In FIG. 1 this response is illustrated by arrow 42 . As a result of the bidding processes in stack groups 25 and 35 , a PW connection 44 is established between n-PE devices 24 and 33 .
[0029] Once a connection path has been created across core network 11 , the plurality of n-PE devices in each stack group continue to communicate with each other via “heartbeat” or “hello” messages which communicate the current state of each device in the group. That is, according to one aspect of the present invention a dynamic SGBP capability is first utilized to establish a connection path across the core network; then the same SGBP mechanism is utilized to continually monitor traffic and maintain the PW connection in real-time based on VLAN activity. For example, if a particular device in the stack group fails, or it is determined that a PW connection should be moved to another n-PE device for load-balancing purposes, a backup connection path is dynamically established through the bidding mechanism, thereby providing redundancy in the SP pseudowire core.
[0030] Practitioners in the arts will appreciate that existing SGBP code created for dial-up interfaces may be used or modified for selection of a primary WAN router (i.e., n-PE device) for a VPLS/VSI or VPWS instance. It should be further understood that in the implementation described above, there is one SGBP-based redundancy state machine per n-PE device. In other words, one SGBP process may handle bids for multiple VPLS or VPWS PWs. Additionally, ordinary practitioners will appreciate that the SGBP bidding mechanism utilized in the present invention operates independently of any STP running to prevent loops within the access domain. Stated differently, there is no limitation against running STP in access domains 20 & 30 of the network topology shown in FIG. 1 .
[0031] The bidding process that happens in each stack group—whether it is for initiating a connection, responding to a connection request, or to re-establish a failed connection—is essentially a negotiation among the multiple n-PE devices in the associated stack group to determine which device has the highest priority for handling a particular establishment. The priority criteria, for example, may include load-balancing considerations, the number of links or volume of traffic a particular device is currently handling, etc. The bidding could also use existing data in the n-PE devices, such as which n-PE device is the root for a spanning tree, in order to determine which device should handle a PW connection.
[0032] It is appreciated that a stack group name may be utilized for redundant devices to bid and load-balance links. The stack group name may be acquired from GARP (Generic Attribute Registration Protocol) VLAN Registration Protocol (GVRP). GVRP is a known application defined in the IEEE 802.1Q standard that allows for the control of 802.1Q VLANs, i.e., 802.1Q-compliant VLAN pruning and dynamic VLAN creation on 802.1Q trunk ports. GVRP basically allows a switch to exchange VLAN configuration information with other GVRP switches, prune unwanted VLANs and their associated broadcast, multicast, and unicast traffic, and dynamically create and manage VLANs on switches connected through 802.1Q trunk ports. GVRP In addition, a configured or automatically determined metric for each member of the stack group may be derived based on a variety of considerations, such as the number of active VPLS instances, which n-PE device is the root for a spanning tree, the number of pseudowires serviced, or the load on a particular physical layer link. In one embodiment of the present invention, the SGBP running in each stack group could utilize GVRP notifications as a mechanism for auto-discovery of remote access domains (i.e., islands). Stated differently, remote islands of interest may be discovered and identified via a GVRP process, or some GVRP derivative, instead of by manual configuration.
[0033] The VPN for each group of links bundles together may also be identified by a VSI that provides cross-domain communication, as defined in the IEEE 802.1ad and 802.1ah specifications.
[0034] FIG. 2 illustrates another aspect of an exemplary VPLS system with an IP/MPLS core network and separate Ethernet access network domains in accordance with one embodiment of the present invention. As previously stated, the network architecture of the present invention does not require a full mesh of PWs to be established between two access domains. Rather, PW connections are only established between those nodes that are active in a service instance at a particular time.
[0035] It is also possible, however, it to establish a full mesh of PWs between the n-PE devices of two different access domain networks, with only one PW being active between the primary n-PE devices. Such an implementation is shown in FIG. 2 , wherein PW 51 provides the connection between primary n-PE devices 24 and 34 . The end-to-end path across the full SP network, which includes access domains 20 & 30 and IP/MPLS core 11 , is depicted by arrow 60 extending between u-PE devices 22 & 32 . The remaining PWs 52 - 54 are shown in FIG. 2 as being blocked, which essentially means that there is no connection path or no PW that is active between the respective devices. Should the primary WAN router change, e.g., due to a failure occur that disables or terminates the PW connection 51 , an alternative PW may be activated as a redundant path. That is, the SGBP mechanism described above dynamically operates to establish a new tunnel path (or re-establish the failed connection between n-PE devices 24 & 34 ) across core network 11 .
[0036] Practitioners in the arts will further appreciate that it is not always necessary to have a PW connection established across core network 11 . In other words, according to the present invention it is possible to implement a network in which the PW is created and maintained in real-time when there is active traffic in a particular VLAN or service instance across SP core 11 . Alternatively, a PW connection may be established between access domains 20 & 30 and be left “up” regardless of VLAN traffic. That is, the network may be configured such that a single PW connection is maintained between provider edge routers for each service instance irrespective of current VLAN activity.
[0037] FIG. 3 is a flowchart diagram that illustrates a method of operation in accordance with another embodiment of the present invention. In the embodiment of FIG. 3 , the process of establishing a connection path across the SP core network begins with the selection of a node for handling the PW connection from the stack group of a first access domain, followed by the sending of a connection request message to the stack group of a second access domain (block 61 ). Receipt of the connection request causes the stack group of the second access domain to initiate bidding for the establishment of the PW connection (block 62 ). After the bidding process ends with the selection of a node in the stack group for handling the connection, a response is sent back to the stack group of the first access domain (block 63 ). At this point, a PW “tunnel” for a VPLS instance is created through the SP core network (block 64 ).
[0038] Once a connection path has been established, a state machine running on a processor (or implemented in hardware or firmware) of each n-PE device in the respective stack groups performs real-time monitoring of the status of each device, as well as the PW connection (block 65 ). Monitoring continues until such time as the connection fails, or load-balancing concerns dictate changing the primary routing device, or some other consideration, at which time the PW connection is re-established via a potentially different path (block 66 ).
[0039] Although the present invention has been described in conjunction with specific embodiments, numerous modifications and alterations are well within the scope of the present invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | A computer network includes first and second Ethernet access domain networks, each of Ethernet access domain networks including a user-facing provider edge (u-PE) device, and a stack group of network-facing provider edge (n-PE) devices coupled with the u-PE device, the n-PE devices running a bidding protocol to select one of the n-PE devices as a primary n-PE device for a single pseudowire connection path between the first and second Ethernet access domain networks. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b). | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved creel for a spinning machine.
Generally speaking, the creel or creel arrangement for a spinning machine, as contemplated by the invention, is of the type wherein to each side of a center or central plane of the spinning machine and extending in the longitudinal direction of such machine, there are provided at least two rows of rotatably suspended roving bobbins. These two rows of roving bobbins extend essentially parallel to the center plane, are lined-up adjacent one another, and have laterally payed-off therefrom the related roving. Additionally, a row of drafting arrangements or drafting arrangement positions is provided substantially parallel to the center plane.
It is well known in practical applications in this field of technology that on ring spinning machines the rovings extending from the roving bobbins to the drafting arrangements are guided over roving deflecting or deflection rods arranged in the longitudinal or lengthwise direction of the ring spinning machine. In the case of creel arrangements composed of two or more rows of roving bobbins arranged behind one another, these deflecting rods originally were placed between the front row of bobbins and the second row of bobbins. However, this arrangement is afflicted with the disadvantage that exchange of the roving bobbins of the rear or back rows is extremely cumbersome, since the bobbins which are intended to be exchanged, in order to be removed or in order to bring them to their suspension devices, have to be placed in a substantially horizontal position and must be passed in such horizontal position beneath the deflecting rod. For donning the bobbins upon so-called Casablanca holders, the bobbin must be brought into its essentially upright vertical position behind the deflecting rod. The elevational position of the deflecting rod is more or less fixed or predetermined, because it is necessary to avoid the danger of damage to the roving unwound from the bobbins due to too high or too low a position of the deflecting rod. The adaptation of the elevational position of the deflecting rod therefore only can be carried out to a limited degree for the purpose of improving these conditions.
Further developments in this field have led to the creation of machines wherein the deflecting rods are placed behind the rearmost row of bobbins. Hence, the deflecting rods no longer get in the way of the bobbins which are to exchanged. On these machines the roving is guided from the bobbins towards the rear, around the deflecting rod and downwardly therefrom and then towards the front into the drafting arrangements. With this design, on the one hand, there is present a relatively large wrap angle of the roving about the related deflecting rod, and consequently, there is present a relatively high frictional resistance, so that there is present the danger of tearing or rupture or otherwise damaging the roving. A further drawback resides in the fact that the insertion of the roving around the deflecting rod, which is placed considerably towards the rear, is extremely difficult, particularly for operators who are not too tall. Finally, in an arrangement of the aforementioned type the roving delivered by the front bobbins must pass between the back or rear bobbins. During such time as the rear bobbins carry a full winding package there exists the danger that the roving passing therebetween might become stuck.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind it is a primary object of the present invention to provide a new and improved connection of creel arrangement or creel for a spinning machine which is not afflicted with the aforementioned drawbacks and limitations of the prior art constructions.
Another and more specific object of the present invention is directed to a new and improved creel arrangement for a spinning machine which facilitates the doffing and donning of bobbins, affords effective and reliable guiding of the rovings from their bobbins to the drafting arrangements, and essentially eliminates the danger of damage to the rovings.
Still a further significant object of the present invention aims at the provision of a new and improved construction of creel for a spinning machine, which allows for effective and safe guiding of the rovings from their bobbins to the drafting arrangements, and which creel is relatively simple in construction and design, relatively economical to manufacture, extremely reliable in operation, not readily subject to breakdown or malfunction, and requires a minimum of maintenance and servicing.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the creel for a spinning machine of the present development is of the type wherein a row of substantially rod-shaped holders is arranged parallel to the center plane to each side of such center plane. These holders are located behind the front row of bobbins. Furthermore, such rod-shaped holders are rigidly mounted at one of their ends, and at the other opposite end thereof each such holder is equipped with at least two guides for rovings, these rovings extending directly from the roving bobbins through the guides to the drafting arrangements.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a schematic top plan view of a creel or creel arrangement for a spinning machine according to the invention;
FIG. 2 is a view similar to that shown with regard to FIG. 1, depicting a somewhat different arrangement of the bobbins and holders;
FIG. 3 is a perspective view of one of the rod-shaped holders or holder members;
FIG. 4 is a perspective view of a further possible construction of a guide element; and
FIG. 5 is a view of a further embodiment of substantially rod-shaped holder or holder element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that only enough of the construction of the textile machine with which the creel arrangement of the present development can be used has been shown in the drawings in order to enable those skilled in this art to readily understand the underlying principles and concepts of the present development while simplifying the showing of the drawings. Turning attention now to FIG. 1, the creel arrangement shown therein contains a front or first row of bobbins 11 and a second row of bobbins 12. Upon the bobbins 11 and 12 there are wound the related rovings 13 and 14. The two rows of bobbins 11 and 12 are arranged to one side of a center or central plane 15 which extends perpendicular to the plane of the drawing of FIG. 1 and in the longitudinal or lengthwise direction of the spinning machine. This center plane 15 divides the creel arrangement into two substantially symmetrical halves. As a matter of convenience in the illustration, and since it will suffice for explaining the teaching and principles of the invention, only one half of the creel arrangement has been specifically depicted in the drawings. It is to be understood that in reality the bobbin rows 11 and 12 extend essentially parallel to the center plane 15 in both directions further than has in fact been depicted in the showing of FIG. 1. The rovings 13 and 14 are payed-off the roving bobbins 11 and 12, respectively, and extend over guide elements 16 carried by substantially rod-shaped holders or holder members, such as the holders 20 of FIG. 3 or the holders 50 of FIG. 5, to a related drafting arrangement or drafting arrangement position 17. Thereafter, there is accomplished between the drafting arrangements 17 and the not particularly illustrated rotating spindles the spinning of the rovings into yarn, as is well known to those skilled in this art.
The roving bobbins 11 and 12 are suspended in conventional manner from suitable holder pins, typically Casablanca holder pins or holders, and are freely rotatably about their lengthwise axes 18. The removal of the rovings 13 and 14 from the corresponding bobbins 11 and 12 is accomplished while rotating these bobbins about their lengthwise axes 18 which are disposed essentially perpendicular to the plane of the drawing. The Casablanca holder pins or holders, in turn, are supported on conventional bobbin support rails which have not here been further shown since such rail constructions are likewise well known and do not form part of the subject matter of the present development.
Turning attention now to FIG. 3 there has been depicted therein a substantially rod-shaped holder or holder member 20 which will be seen to comprise two rod portions or sections 21 and 22, each of which contains a threaded end section or region 23 and 24, respectively. A pre-tensioned helical spring 25 or equivalent structure is fixedly connected to the end sections 23 and 24. At the lower end of the rod portion 22 there is attached the related guide element 16. In the embodiment under discussion each such guide element 16 possesses two guides or guide facilities 27 and 28 for coverings. The holders 20 are mounted with their uppermost rod portion 21, which is shown in FIG. 3, at the spinning machine frame, for instance at a support rail, and, in the embodiment depicted, extend downwardly from their attachment location.
There is payed-off from each of the bobbins 11, during the rotation thereof, the roving 13 carried thereby and such roving 13 is then guided by means of one of the guides, such as for instance the guide 27 of the related guide element 16, to its corresponding drafting arrangement 17. In analogous fashion there is payed-off from each bobbin 12 its related roving 14 and such is then guided through the other guide 28 of the related guide element 16 to its related drafting arrangement 17.
If the bobbins 11 and 12 which are arranged behind one another or in tandem, viewed in a direction which is perpendicular to the center plane 15, are construed to constitute a group of bobbins, then a respective guide element 16 and its related holder or holder member 20 will be understood to be arranged between two neighboring bobbin groups, and specifically, between the front row of bobbins containing the bobbins 11 and the second or rear row of bobbins containing the bobbins 12. The roving 13 from a bobbin 11 and the roving 14 from a bobbin 12 of such group travel over or through the guides 27 and 28, respectively, of the related guide element 16 and its holder 20. Equally, it will be appreciated that the mentioned bobbins 11 and 12 which are arranged immediately behind one another belong to the same group which neighbor the corresponding holder or holder facility 20.
In the event that the roving 13 or 14, as the case may be, on the related bobbin 11 or 12 is spent or depleted, then it is apparent that such exhausted bobbin must be replaced by a new full bobbin 11 or 12, as the case may be. As far as the front bobbins 11 are concerned that does not constitute any significant problem or operating procedure. At the front row of bobbins 11 the empty bobbins are simply released from their suspension or support at the rotational bearing, removed and thereafter there is donned a new full bobbin in the suspension device.
The procedure becomes more complicated, however, when one of the bobbins 12 of the rear or back row is depleted. In order to exchange a bobbin 12 of the second bobbin now, it is necessary to initially remove the bobbin 11 which is positioned immediately forwardly thereof, in other words that bobbin of the front row of the same group. Thereafter, the exhausted bobbin 12 becomes accessible by reaching through the formed alley, can be released from its suspension and again withdrawn through such open alley between the two front bobbins 11, and then a new full bobbin 12 can be inserted through the alley and donned onto the corresponding suspension device. It should be apparent that these manipulations can be accomplished easier than if there were present, as in the prior art, the horizontal roving deflection or deflecting rod extending parallel to the center plane 15 at the location of the guide elements 16. The rod-shaped holders 20 located at the center or central region between the thereat neighboring bobbin groups permit passage of the full bobbins which are to be inserted between neighboring holders 20 while the bobbins are in their essentially upright vertical position. It is recommended, in particular, and as shown in FIG. 3, to use as the guide element 16 a guide element designed as a substantially flat body or body member in which there are formed, by means of the depicted recesses 27' and 28', the corresponding guides 27 and 28, respectively, and which is arranged essentially perpendicular to the center plane 15. In this manner there can be practically eliminated the presence or parts which protrude into the alley formed between the bobbin groups during the bobbin exchange operation.
If, under certain circumstances, the holders or holder members 20 still present an obstacle during the exchange of the bobbins 12, then it is a desirable aspect of the invention to design them so as to be deflectable or movable. A specific construction complying with this requirement is fulfilled by the holder construction of FIG. 3. The holder 20 thereof is equipped with a suitable flexible element, in the embodiment under discussion with the aforementioned helical spring 25, between the end portions 23 and 24. During the donning or doffing of a bobbin 12 it is therefore possible, by appropriately bending the spring 25, to laterally manually displace away, in any random direction, the rod portion or rod 22, so that it practically no longer constitutes an obstruction or hindrance during the bobbin exchange operation. Since the spring 25 is pre-biased or pre-tensioned, the rod portion 22, following its release, automatically moves or snaps back into its original starting or work position.
It should be readily apparent that the insertion of the rovings 13 and 14 through their related guides 27 and 28 can be accomplished with considerably greater ease than if the roving had to be inserted around a roving deflecting rod located at the site of the center plane 15. A particularly effortless insertion of the rovings 13 and 14 is possible if the guides 27 and 28, and specifically the recesses 27' and 28' forming the same, are of substantially U-shaped configuration, as depicted in FIG. 3. It is here to be considered that the bobbins 11 and 12 are suspended at a considerable elevational position, and that the bobbin space can extend far to the rear. Furthermore, when using, for instance, the guides 27 and 28 as shown in FIG. 3, there is obtained, in contrast to a deflection of the rovings about a rod, a cleaner and more effective guiding of such rovings because the latter are necessarily and positively held separated from one another.
In the exemplary embodiment depicted in FIG. 2 there is present a front row of bobbins 31 carrying rovings 34, and a second of bobbins 32 carrying the rovings 35. Additionally, there will be recognized a third row of bobbins 33 carrying the rovings 36 and located at the center of the machine, i.e. at the site of the center or central plane 15. A respective roving 34 and 35 extends from each of the related bobbins 31 and 32 belonging to a bobbin group and leads to a guide element 37, of the type depicted in FIG. 4, and from such guide element 37 then travels to the corresponding drafting arrangement 38. As to the bobbins 33 there extends from each second bobbin a roving 36 to a related one of the guide elements 37 and its corresponding drafting arrangement 38. From the other bobbins 33 the roving 36 is fed to the left-hand portion of the spinning machine, located to the left side of the center plane 15 of the arrangement of FIG. 2. This half of the creel is analogously designed to the part of the creel appearing at the right-hand side. Hence, there can extend three respective rovings to each second guide element 37 and to each intermediately dispositioned guide element 37 two respective rovings.
As already previously mentioned, an embodiment of guide element containing three guides 41, 42 and 43 has been disclosed in FIG. 4 with regard to the therein depicted guide element 37. This guide element 37 can be operatively connected to a suitable holder member, for instance a holder 20 of the type depicted in FIG. 3, wherein, as should be readily evident, the guide element 16 thereof is then simply replaced by the guide element 37 shown in FIG. 4. Both the construction of guide element 16 of FIG. 3 and that of the guide element 37 of FIG. 4, ensure for a clean separation of the rovings from one another, and by virtue of the substantially U-shaped configuration of their guides 27, 28 (FIG. 3) and 41, 42 and 43 (FIG. 4) there is afforded an easy insertion or threading-in of the related roving. The guides 41, 42 and 43 are distributed at essentially the same angular spacing from one another about the rod portion or rod 22 forming a center.
With the embodiment depicted in FIG. 2, during the bobbin exchange process of the bobbins 33 the latter must be introduced by means of an alley formed by two respective bobbins 31 and 32 of two bobbin groups. Therefore, these alleys are longer than the ones which are formed with the creel construction of the arrangement of FIG. 1 previously discussed. Thus, the exchange of the bobbins is comparatively more difficult and cumbersome, so that the provision of the holders constructed according to the teachings of the invention, in this case proves to be especially useful for the exchange of the bobbins 33. In particular, if the holders are constructed to be deflectable and can be manually moved towards the side, then there is realized an appreciable facilitation in the bobbin exchange work. In the exemplary embodiment depicted in FIG. 2, the holders and their guide elements are located between the second bobbin row containing the bobbins 32 and the third row of bobbins 33 extending along the center of the spinning machine. Consequently, the bobbins 31 of the front row and the bobbins 32 of the second forwardmost row can be exchanged without having to move past the holders. The holders therefore only need to be taken into account during the exchange of the bobbins 33. Even though with this exemplary arrangement the guide elements 37 are located relatively far towards the rear, nonetheless the insertion of the rovings into the guide elements 37 can be carried out quite easily because, instead of the need of placing or inserting the roving about a related rod, it is here necessary, according to the invention, to only insert the roving into its corresponding guide, and, in particular, if there is used the substantially U-shaped guide as shown in the drawings, then there is only required insertion of the roving from above into the recess forming such related guide.
Continuing, in FIG. 5 there has been depicted an exemplary embodiment of holder or holder member 50 which possesses two rod portions or sections 51 and 52. The rod portion 52 carries at its lower end a guide element 55 containing the guides 53 and 54, the shape of which conforms to a certain extent to an eyelet. The rod portion 51 is fixedly connected with a hinge or rotatable joint 56, whereas the rod portion 52 is pivotably connected at the hinge or pivot joint 56. This hinge or pivot joint 56 may comprise two oppositely situated pre-biased disks 56a between which there is positioned the rod portion 52. By providing appropriate furrows or recesses, merely generally indicated by reference character 56b, at the faces of the disks 56a which confront one another there can be defined two stable angular positions of the rod portions 51 and 52 with regard to one another. One of these positions is constituted by the illustrated extended arrangement of the rod portions 51 and 52 where they are essentially in alignment with one another. The other position is depicted by the phantom line showing, and specifically wherein the rod portion 51 remains in its original position, whereas the other rod portion 52 is angled towards the right of the showing of FIG. 5 into the broken line illustrated position thereof. The upper rod portion 51 is fixedly mounted to part of the machine frame.
The lower rod portion 52, prior to exchange of a bobbin, is tilted or moved towards the side into the broken line position, so that during the bobbin exchange operation it completely frees or clears the alley required during this time. After the bobbin exchange operation has been completed the rod portion 52 is then again tilted back into its essentially vertical position constituting the starting or work position.
By again reverting to FIG. 3, it is here additionally mentioned that in the illustrated exemplary embodiment the pitch or thread increments of the not particularly referenced threads of the threaded end portions 23 and 24 and the pitch of the spring 25 are essentially of the same magnitude. Under these circumstances the threaded end portions 23 and 24 can be threadably connected with the spring 25. Once they have been threadably interconnected these parts are fixedly and positively joined to one another, since when the spring is turned in the sense of releasing the thread connection the spring is tightened in its circumferential direction, i.e. in the direction of its coils or windings, in a manner such that it becomes fixedly clamped. This spring 25 thus is self-clamping. Consequently, no additional measures or facilities are required, such as for instance screws, for interconnecting the parts 23, 24 and 25. A steel spring constitutes an extremely durable, elastic or resilient member. Because of the unavoidable fly waste which is present during textile processing, it is recommended that the spring 25 be covered with a soft protective sheath or covering 29. The same also, of course, holds true for the pivot or hinge joint 56 depicted in the arrangement of FIG. 5.
The elastic member coupling the rod portions 21 and 22 also can be formed of rubber which, when possessing a hose-shaped design, can be pulled over the end portions or sections 23 and 24, or else can be mounted in bores provided in the end portions or sections 23 and 24 if the elastic member is provided in the form of a solid cylinder.
In the embodiment depicted in FIG. 5, the broken line tilted position of the rod portion 52 forms an obtuse angle with the downwardly depending rod portion 51. According to a further possible construction of the invention, in such tilted-out position of the rod portion 52 such can form, instead of the obtuse angle or in addition to such obtuse angle, also a right angle.
Additionally, the number of guides provided on a related holder can be chosen as desired, corresponding to the prevailing requirements and the encountered conditions at the creel arrangement.
A movement of the holders 20 and 50 as completely out of the way as possible is realized if, with the constructions depicted by way of example in FIGS. 3 and 5, the rod portions 21 and 51 are designed to be as short as possible. In most instances the rod portions 21 and 51 are constructed to be appreciably shorter in length than the rod portions 22 and 52, respectively.
In the embodiments under discussion it has been assumed that the holders 20 and 50 are mounted on a support rail provided for this purpose. However, there are also possible embodiments according to the invention, while practicing the underlying principles and teachings thereof, wherein the holders are mounted on a bobbin support rail, and the fixed rod portion is designated to be angled or flexed, or if the holder is designed to be straight such holder can be positioned at an inclination or obliquely in its working position.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly, | With the creel for a spinning machine according to the invention at least two rows of rotatably suspended roving bobbins, which extend essentially in parallelism with respect to one another, are adjacently lined-up. Normally in ring spinning machines there are employed for such creels roving deflecting rods which extend horizontally in the longitudinal direction of the ring spinning machine. The rovings extending from the roving bobbins to the drafting arrangements are guided around the deflecting rods for the purpose of guiding the rovings. If the deflecting rod is located behind the bobbins, then insertion of the rovings about the rods is extremely cumbersome, and additionally, there exists the danger of damaging the rovings. If the deflecting rod is located further towards the front, then exchange of the bobbins becomes tedious. These drawbacks are eliminated with the invention in that a row of substantially rod-shaped holders is arranged behind the front row of roving bobbins. One end of each of the holders is rigidly mounted, and the other end of each holder is provided with at least two guides for rovings. These rovings extend directly from the related roving bobbins by means of the guides to the drafting arrangements. | 3 |
FIELD OF THE INVENTION
This invention relates to injection of inert and/or reactive gases into a bath of molten metal by means of a submerged tuyere.
BACKGROUND OF THE INVENTION
Concentric pipe tuyeres, have been applied and are used widely throughout the metals industry. An early patent on such a tuyere was French Patent 1,450,718, which described two concentric pipes to produce a core jet of oxygen surrounded by an annular jet of cooling gas. Since then, a large number of improvements have been made using either two concentric pipes as in French patent or two or more than two concentric pipes as shown in the following United States Patent
______________________________________2,855,293 3,893,658 4,272,2863,706,549 3,897,048 4,336,0643,832,161 4,022,447 4,450,0053,891,492 4,138,098 4,754,951 4,249,719 4,887,800______________________________________
In order to operate satisfactorily any tuyere for injecting fuel gas and oxygen into a molten metal bath, the tuyere must be operated within very narrow limits. If the temperature is allowed to increase too much the tuyere pipes melt or burn away and the tuyere fails in a short time. If the temperature is too low, a solid accretion forms at the tip of the tuyere and the tuyere becomes blocked, the flow of gas out of the tuyere ceases and the gas is forced into the refractory surrounding the tuyere, with destruction of the refractory and failure of the tuyere.
In order to operate satisfactorily for extended periods of time, a tuyere for injecting fuel gas and oxygen into molten metals must remain cool, open, and must be protected by a thermal accretion of the correct size. Additionally, it must be constructed of materials that are compatible with the reactants at the operating temperatures, pressures, and velocities.
SUMMARY OF THE INVENTION
This invention relates to a specifically designed tuyere, or gas injector, which is useful in simultaneously injecting relatively large flows of oxygen and natural gas in varying ratios with a broad "turn-down" into molten metal without causing the formation of excessively large accretions which can cause back pressure build-ups and gas leakage back through the refractory lining of a vessel for melting or refining molten metal, especially molten ferrous metal.
More particularly, it relates to a tuyere comprised of three concentric pipes or tubes, through which streams of oxygen and natural gas are introduced into a molten metal bath, such as pig iron, the oxygen stream being an inner annulus disposed between an outer annulus of natural gas and an inner core of natural gas, the lengths and diameters of the center tube and oxygen tube are selected so that the ratio of the fully expanded center tube jet velocity to the fully expanded oxygen annulus jet velocity ranges from 0.8 to 1.4 and the length and diameter of the outer tube is selected such that the ratio of the fully expanded outer annulus jet velocity to the fully expanded inner annulus jet velocity ranges from 1.0 to 1.6.
According to the invention means are provided to simultaneously inject relatively large quantities of oxygen and natural gas into a molten metal bath, in varying ratios, while avoiding the previously experienced operating problem of too large an accretion build-up on the end of the tuyere (gas injector).
The invention provides a tuyere design and operation which produces formation of a properly-sized protective accretion over the end of the tuyere when gases (e.g. oxygen, natural gas) are injected into molten ferrous melts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view taken through the center of the tuyere.
FIG. 2 is an enlarged schematic view of the tip of the tuyere of FIG. 1 showing an accretion at the tip of the tuyere.
FIG. 3 is an enlarged sectional view of the tuyere of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The tuyere of the present invention is an injector for the simultaneous introduction of fuel gas (natural gas, carbon monoxide, hydrogen, propane or any hydrocarbon gas) and oxygen into solid steel scrap, molten pig iron, molten steel, molten oxides (glass or refractories), solid non-ferrous metal scrap, or molten non-ferrous metals. The tuyere can be used to inject fuel gas and oxygen with broad turndown and at various flow rate ratios for the purpose of heating, melting, reducing, or oxidizing the metal or, oxide. It is designed to resist blockage by frozen metal or oxide, remain cool, and control the formation of thermal accretions while injecting the reactant streams into the metal or oxide.
The tuyere of this invention is made up of three concentric metal (copper and stainless steel) tubes open on one end and connected to individual plenum chambers on their other ends as shown in the drawings. This arrangement creates two annular passages that surround a central core. Fuel gas enters the tuyere and flows through plenum chamber to the outer annulus and the core tube. Oxygen enters the tuyere and flows through a plenum to the inner annulus. Oxygen and fuel gas are injected into the molten metal or oxide from the open ends of the tubes. The tuyere is encased in a refractory brick that is set into the wall of the converter vessel or furnace that contains the metal or oxide. The lengths and diameters of the center and first annulus tubes are selected so that the ratio of the fully expanded center tube jet velocity to the fully expanded first annulus jet velocity ranges from 0.8 to 1.4. The length and diameter of the outer annulus tube is selected such that the ratio of the fully expanded outer annulus jet velocity to the fully expanded inner annulus jet velocity ranges from 1 to 1.6.
The tuyere is cooled by convective heat exchange between the expanding gases and tube walls and in some cases, by the endothermic cracking of the fuel gas. Blockage is prevented by the high speed (supersonic), under-expanded gas jets that are created on the open ends of the tubes. The size of thermal accretions on the end of the tuyere are controlled by varying the distribution of natural gas between the core and the outer annulus and by setting the amount of mixing between the oxygen and fuel streams.
The tuyere of this invention is characterized by the expansion of the fuel and oxygen streams as they flow from plenum chambers to the open ends of the concentric tubes. The gases enter the tuyere at pressures from 200 to 500 PSIG and expand to the static pressure of the molten bath or scrap charge (typically from 0 to 15 PSIG) at the exit of the tuyere. As the gases flow from the plenum chambers at the back of the tuyere to the exit at the front end of the tuyere, they expand and accelerate. The gas velocities at the plenum end of the tubes are low, approximately up to 10 ft/sec, while those at the tuyere exit are Mach 1 or "choked". The gases are not fully expanded at the tuyere exit and continue to expand to the bath pressure outside the tuyere exit. In this final expansion, the gases accelerate to supersonic velocities between Mach 1 and Mach 3.
As the fuel and oxygen accelerate inside the tuyere, enthalpy and heat are converted into the kinetic energy of the gas streams. The high ratios (30:1 -6:1) of gas inlet pressures to outlet pressures cause the gases to accelerate and allow them to convert heat transferred from the tube walls to kinetic energy (thereby cooling the tube surface). Heat is transferred from the tube wall to the gas flows by convection. The convective heat transfer coefficient is high because of the high Reynolds number (turbulence) of the flows. Since the Reynolds number and Prandtl number are constant along the length of the tubes, the heat transfer coefficient also remains constant. Cooling is so effective with this design that the metal tubes stay below 500° F. even though surrounded by refractory at 1000°-3000° F.
Tuyeres frequently fail because of blockage by molten metal or oxide that runs into or floods the tuyere tubes and freezes. We have found that flooding can be prevented by running the fuel gas and oxygen at high enough pressure ratios to create an underexpanded supersonic gas jet in the molten metal or oxide at the end of the tuyere.
The static pressure inside the jet and at the tuyere exit is greater than the static pressure of the molten metal or oxide. This jet static pressure prevents liquid from flowing back into the tuyere outlet. At pressures below those required for an underexpanded jet, periodic bubbling flow results and allows molten metal contact with and flow back into the tuyere exit.
The diameter and lengths of the tubes used in the tuyere of this invention are selected to create supersonic jets with fully expanded Mach numbers between 1.1 and 3. Standard gas dynamics correlations (Fanno and Rayleigh flow) for high speed flow in a constant area duct were used to calculate the required tube diameters for a given flow rate and pressure ratio. These correlations were qualified with extensive data collected in actual operation of the tuyere. The tuyere tubes can be any combination of length and diameter that creates a supersonic jet on the end of the tuyere for the desired flow and pressure ratio.
Of course the tuyere must be constructed of materials, preferably stainless steel or copper, of sufficient thickness to withstand the internal pressures at the maximum operating temperatures.
High speed underexpanded gas jets will prevent blockage of the tuyere due to molten metal or oxide flow into the passages but will not prevent the formation of a frozen metal or oxide accretion over the end of the tuyere. A typical accretion is shown in FIG. 2 and is a mass of metal or oxide that is cooled to its freezing point by the endothermic decomposition of a portion of the fuel gas stream. Accretions are porous enough to allow gas flow and will shield the end of the tuyere from superheated molten metal or oxide. If an accretion is allowed to grow too large, it will restrict gas flow and force gases through the vessel refractories. These gases will work their way through the vessel wall to the outside where they will burn. If trapped in the refractories, the combustible oxygen and fuel gas could create an explosion.
The size of the accretion that builds on the end of a gas injection tuyere can be calculated by performing a heat balance. For a given steady sized accretion the heat input must equal the heat that leaves the accretion. The accretion will grow if it experiences a net cooling effect or it will diminish in size if it experiences a net heating effect. One method of computation for a two pipe tuyere is set forth in a paper given at the "Savard Lee International Symposium on Bath Smelting" in Montreal Oct. 18-22, 1992 entitled "On The Formation Of Thermal Accretions (Mushrooms) in Steelmaking Vessels" by Guthrie, Lee and Sahai. Similar calculations can be made for the three pipe tuyere of the present invention.
Heat is transferred to or from the accretion in the following four ways:
1. To the accretion from the surrounding molten metal by convection.
2. To the accretion from the combustion of a portion of the fuel gas stream.
3. From the accretion to endothermic decomposition of the unburned portion of the fuel gas.
4. From the accretion to heating the natural gas and oxygen streams to the freezing temperature of the molten metal.
It has been found that as the natural gas flow rate is increased, the fraction of unburned natural gas must be decreased to maintain an accretion of constant size.
It has been calculated that for methane-oxygen injection into steel, 10 to 25% of the natural gas must be burned close to the exit of the tuyere to control the size of the accretion. If all of the natural gas is unburned then accretions will become excessively large. On the other hand if 30% or more of the natural gas is burned close to the end of the tuyere then the accretions will become too small and the end of the tuyere will not be protected.
The amount of natural gas that reacts with oxygen exiting the end of the tuyere is dependent on the amount of mixing between the streams. The tuyere of this invention creates a central jet of natural gas that is surrounded by two concentric annular jets. The core natural gas jet is surrounded by an annular oxygen jet that is in turn surrounded by an annular natural gas jet. The rate of mixing between concentric jets depends on the ratio of their fully expanded velocities. The lengths and diameters of the center and inner annulus tubes used in this invention are chosen so that the ratio of the fully expanded core velocity to the fully expanded inner annulus velocity ranged from 0.8 to 1.4.
The length and diameter of the outer annulus tube are chosen so that the ratio of the fully expanded outer annulus velocity to the inner annulus velocity ranged from 1 to 1.6.
The range of velocity ratios given above successfully control the amount of mixing between the natural gas and oxygen jets and hence the amount of combustion close to the exit of the tuyere. These ratios keep the fraction of unburned natural gas above 75% for oxygen to fuel ratios between 2 and 1.
Mixing between natural gas and oxygen is further controlled by distribution of the natural gas between the core jet and outer annular jet. In accordance with this invention 10 to 504 of the natural gas is supplied through the outer annulus. In a preferred operation 10% of the natural gas is supplied to the outer annulus and 90% to the core. All of the oxygen is supplied through the inner annulus. The tuyere has been successfully operated at overall oxygen flow to natural gas flow ratios of 0.8 to 2.5.
The tuyere of this invention can also be used to inject fuel gas and oxygen into solid metal scrap. The scrap mixes the reactants and stabilizes a flame in the voids between the scrap. With this capability, this invention can be used to preheat scrap metal to its melting temperature and subsequently inject reactant gases (oxygen and fuel) into the molten metal bath.
FIG. 1 illustrates the tuyere 10 of this invention. A central pipe 12 preferably of copper is fastened by welding, brazing or soldering to a collar 14 to which a nipple 16 is secured, by welding, brazing or soldering. Utilizing threaded passage 11, nipple 16 is connected to a supply of natural gas (not shown) which forms the core of the stream exiting the end of the tuyere. A section of pipe 20 extends from collar 14 to a collar 22. The space between collars 14 and 22 defines an oxygen plenum space 24 which is connected to a supply of oxygen through a fitting 26, welded to pipe 20. An opening is provided in the wall of pipe 20 where fitting 26 is welded to pipe 20. Collar 14 supports the central pipe 12.
Supported by and extending from a shoulder on collar 22 is a stainless steel pipe section 30 in which an oxygen supply pipe 32 is disposed, extending from collar 22 to the tip of the tuyere. A fitting 34 welded to pipe 30 connecting pipe 30 with a supply of natural gas, (not shown). Pipe 30 defines a natural gas plenum which supplies natural gas to a third concentric gas supply pipe 40.
Gas supply pipe 40 is mounted in a support plate 42. Pipe 40 is concentric with and surrounds pipes 12 and 32. Pipe 40 is encased in a protective refractory 44.
Tuyere 10 is installed in a refining vessel, e.g. as shown in any of the above noted U.S. Patents and when in use, with oxygen and natural gas flowing through pipes 32, 12 and 40, an accretion 50 builds up at the end of the tuyere as shown in FIG. 2. Accretion 50 is in the molten metal 52.
By suitably proportioning the dimensions (length and diameter) of tubes 12, 32 and 40 and by providing appropriate gas flows through the pipes the accretion 50 remains at an optimum size and then does not get any larger or smaller.
Examples 1 and 2 below were experiments conducted according to the teaching of the present invention.
__________________________________________________________________________Example #1__________________________________________________________________________Trial Date: 3 November 1988 Location: Greenville, PAVessel: Universal Refining VesselMolten Steel Weight: 6.5 Tons Steel Composition: 0.22C 0.53Mn 0.01Si__________________________________________________________________________Tuyere DimensionsTubes I.D. (in.) O.D. (in.) Length (in.)__________________________________________________________________________Core 0.186 0.250 15.0Inner Annulus 0.302 0.540 11.0Outer Annulus -- -- --__________________________________________________________________________ Flowrate Velocity Mach.Gas Injection Parameters Gas (SCFM) (ft/sec) No.__________________________________________________________________________Core O.sub.2 166 2940 2.7Inner Annulus (A1) N.G. 83 3990 2.2Outer Annulus (A2) -- -- -- --__________________________________________________________________________Gas Passage Velocity Ratios: V.sub.core /V.sub.A1 : 0.74 V.sub.A2 /V.sub.A1 : --Accretion Formation:Size: 12" dia.Shape: Dome Covering Entire TuyereResult: Gas flow blocked, resulting in leakage through the refractory and subsequent external flames.__________________________________________________________________________
__________________________________________________________________________Example #2__________________________________________________________________________Trial Date: 18 January 1990 Location: Bethlehem, PAVessel: Mini-BOFMolten Steel Weight: 2.0 Tons Steel Composition: 3.9C 0.74Mn 0.72SiTuyere DimensionsTubes I.D. (in.) O.D. (in.) Length (in.)__________________________________________________________________________Core 0.124 0.188 28.6Inner Annulus 0.265 0.375 24.0Outer Annulus 0.388 0.540 8.0__________________________________________________________________________ Flowrate Velocity Mach.Gas Injection Parameters Gas (SCFM) (ft/sec) No.__________________________________________________________________________Core N.G. 34 2840 1.9Inner Annulus (A1) O.sub.2 97 2450 2.2Outer Annulus (A2) N.G. 16 3410 1.8__________________________________________________________________________Gas Passage Velocity Ratios: V.sub.core /V.sub.A1 : 1.16 V.sub.A2 /V.sub.A1 : 1.39Accretion Formation:Size: 2" dia.Shape: Toroid Around Outside of TuyereResult: Tuyere operated as designed with little or no wear and no gas leakage.__________________________________________________________________________
From the foregoing examples it can be shown that a tuyere and method of operation according to the present invention (Example 2) overcomes the problems with prior art devices simulated by Example 1.
Having now described the preferred embodiment of our invention, it is not intended that it be limited except as may be required by the appended claims. | A tuyere for refining molten metals or melting metal scrap or oxides charged into a vessel. The tuyere comprises three concentric pipes of copper or stainless steel encased in refractory. An annular stream of natural gas surrounds an annular stream of oxygen which in turn surrounds a core stream of natural gas. All three streams are expanded as they flow through the tuyere and as a result an accretion forms at the tip of the tuyere. The accretion protects the tuyere and the gas streams are controlled so that the accretion is maintained at a desired size which neither blocks the tuyere, nor permits burnback of the pipes. | 8 |
RELATED APPLICATION
This application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 60/310,666, filed on Aug. 7, 2001, the contents of which are incorporated in this application by reference.
TECHNICAL FIELD
The present invention relates generally to a vehicle utility rack and, more particularly, to a hinged utility rack that allows the temporary roof of a vehicle to be removed without disengaging the utility rack from the vehicle.
BACKGROUND OF THE INVENTION
Even as vehicles become larger and provide increased storage space, the desire to carry more cargo in or on the vehicle remains. One response to that desire is a cargo rack, which is placed on the vehicle outside the passenger compartment. Cargo racks generally are adapted to carry skis, bicycles, storage units, and other items.
The art is replete with different designs and styles of cargo racks. One common feature of these racks is that they are typically secured to the vehicle roof. More specifically, they are rigidly mounted in a fixed position to the roof of the vehicle. The advantages of roof racks are many: they maintain sight lines, minimize aesthetic drawbacks, avoid interference with doors and windows, and allow maximum use of passenger space inside the vehicle.
In basic form, the roof rack has a pair of spaced parallel rails or load bars, fixedly attached to the roof and aligned parallel to the centerline of the roof or transversely to it. The rails are elevated a slight distance from the roof surface, generally three to five inches. The ends of the rails have end brackets which attach to the roof by sheet metal screws or the like and hold the rails at the predetermined height. In a common configuration, the brackets for the two transverse rails are adjustably mounted in fixed linear tracks along each side edge of the roof, allowing the user to set the spacing between the two rails. After-market versions of these generalized or multipurpose roof racks are provided that can be installed and removed from the vehicle and may include end brackets that screw into the roof gutters of the vehicle or clamp into the top of the side door openings.
Each particular type of cargo roof rack addresses a specific problem. For example, U.S. Pat. No. 6,029,873 issued to Won et al. teaches a roof rack assembly that enhances and improves the overall appearance and aerodynamics of a vehicle with the roof rack. The roof of the vehicle contains grooves making it possible to retract the roof rack to a stored position when not in use. Although aesthetically and aerodynamically improved, this roof rack requires extensive modifications to the vehicle roof.
Another problem presented by roof racks is the difficulty experienced by users when securing or storing cargo to or in the rack. Most vehicles are sufficiently tall that the roof is inaccessible to individuals of normal height. U.S. Pat. No. 6,308,874 issued to Kim et al. provides a roof rack that slides down the rear of the vehicle to allow a user to access the stowed cargo while standing on ground level. This rack eliminates the need for an elevation mechanism such as a step stool. The portion of the rack which does not slide must still be securely mounted to the vehicle roof.
The roof is a stable structure, and can support a conventional roof rack, in most vehicles. In some vehicles, however, the roof is removable, is not structurally sound, or both. Most vehicles having removable roofs are designed to allow open-air enjoyment. Such roofs can be either removable “hard” tops (i.e., temporary shells) or “soft” tops made of fabric, coated canvas, tarps, and the like. By removing the soft or hard top roofs, the enclosed vehicle is converted into an open-air vehicle.
Among the various types of convertible vehicles, sport-utility vehicles (SUV's) and all-terrain vehicles (ATV's) have gained widespread popularity in recent years. Generally, these vehicles have a box-shaped cab and include various features such as four-wheel drive and heavy-duty suspensions which allow them to be used in most environments including the off-road environment. Therefore, vehicles of these types are particularly well suited for transporting passengers to remote locations for participation in outdoor sports. Examples of such outdoor sports include skiing, snowboarding, canoeing, bicycling, fishing, and camping.
Many of these sports require specialized equipment for their participants. Among other bulky equipment, bicycling requires a bicycle; fishing requires fishing poles; canoeing requires a canoe; skiing requires the skis, poles, and boots; snowboarding requires a snowboard; and camping requires a tent. Such specialized equipment must be carried along with the user to the remote outdoor location.
A major disadvantage of such SUV's and ATV's is their relative lack of cargo space. Space within the passenger compartment is limited. For situations where large items are desired to be transported, the interior space of most SUV's and ATV's is inadequate. Given both the limited interior space and the size and shape of the equipment which owners of SUV's and ATV's desire to transport, such equipment is most effectively carried outside the vehicle on roof-mounted racks. Thus, roof racks are common on SUV's and on ATV's.
As outlined above, the art is replete with different designs and styles of roof racks. Nevertheless, relatively few solutions exist for convertible SUV's and ATV's. This shortage exists because most vehicle roof racks must be mounted to the roof of a hardtop vehicle for support. Convertible SUV's and ATV's do not have hard tops and, therefore, most conventional roof racks cannot be used with these vehicles. A fixed roof rack that requires mounting the rack to the vehicle roof is simply impractical with removable soft or hard top roofs. Although these difficulties are inherent for vehicle types known as SUV's and ATV's, the same problems exist with convertible automobiles and with vans and pickup trucks having caps or removable hardtops installed over their cargo decks.
Roof racks that do not require mounting to the roof do exist. Such roof racks present their own set of problems. The roof rack may be affixed to the vehicle through longitudinal support bars as taught, for example, by U.S. Design Pat. No. 415,718 issued to Aghaci. The longitudinal support bars are affixed to the front, sides, or back of the vehicle and travel up the vehicle frame to the vehicle roof. The roof rack bed is mounted to the longitudinal support bars with secure fixtures. The roof rack bed is not affixed to the vehicle roof and, therefore, the roof rack bed and longitudinal support bar connections are critical load-bearing, structural joints. As a consequence, the roof rack bed and longitudinal bars are commonly a continuous structure welded together for maximum strength. Once affixed to the vehicle, these roof racks are tedious to remove and are impractical for use with vehicles having soft or hard top roofs because opening, closing, removal, and replacement of the roof is difficult.
U.S. Pat. No. 6,068,168 issued to Kreisler discloses a vehicle rack assembly for mounting on a vehicle having a rollbar. The assembly offers a unitary rack member having side walls and a floor and bracket members for mounting the floor of the rack to the rollbar of the vehicle. For use with a convertible SUV or ATV having a roof, the assembly can further have grommet assemblies with seals for mounting around holes formed in the roof of the vehicle for receiving a portion of the bracket members so that the roof of the vehicle passes between the rollbar and the unitary rack member. Thus, modification of the roof (holes and seals must be provided) is required for the rack assembly to engage the rollbar.
None of these conventional solutions permits a removable soft top to be raised and lowered easily or a removable hard top to be removed and replaced easily. To overcome these shortcomings of a roof rack that requires modifications to the vehicle in order to mount the roof rack or a roof rack that impedes removal of a soft or hard top roof, a new hinged utility rack is provided. A principal object of the invention is to provide a hinged utility rack that can be raised and lowered thereby facilitating operation of the removable roof of the vehicle. A related object of the present invention is to provide an improved utility rack assembly that allows the temporary hard or soft top roof of a vehicle to be removed without having to remove the utility rack assembly. Another object is to provide a utility rack assembly that is designed so as not to impinge upon the vehicle roof.
It is still another object of the present invention to provide a utility rack assembly that is attractive and does not require any aesthetically undesirable supports. A further object is to provide a utility rack assembly constructed of substantially rust-proof, durable, light-weight material able to support weight from cargo. Still yet a further object is to provide a utility rack assembly designed in component parts for ease of shipping and installation. Another object of the invention is to provide a utility rack assembly which is relatively inexpensive to construct and maintain.
The invention also seeks to provide a utility rack which can accommodate one or more lights. An additional object of the present invention is to provide a utility rack which may be manually lowered or raised and locked. A related object is to provide such a device which may be electromechanically lowered or raised and locked. Yet another object of the present invention is to provide a utility rack which can be fitted to a variety of vehicle roof sizes and shapes.
SUMMARY OF THE INVENTION
To achieve these and other objects and in view of its purposes, the present invention provides a utility rack for a vehicle having a temporary (i.e., a removable or retractable hard or soft) top or roof and holes for mounting conventional vehicle components. The utility rack is adapted to be disposed on and external to the vehicle. Included in the utility rack is a bed for holding and transporting cargo and for supporting objects and people. A first support bar includes a first horizontal support section and two first vertical mounting sections attached to the vehicle by first mounting plate assemblies using the existing holes of the vehicle, and supports the bed. A second support bar includes a second horizontal support section and two second vertical mounting sections attached to the vehicle by second mounting plate assemblies using the existing holes of the vehicle, and supports the bed when connected to the bed.
A hinge pivotally connects the first horizontal support section of the first support bar to the bed, enabling the bed to pivot about the first horizontal support section of the first support bar. A clamping knob assembly releasably connects the second horizontal support section of the second support bar to the bed. Thus, the bed pivots between (a) a closed position in which the bed covers the roof or top of the vehicle and the clamping knob assembly connects the second horizontal support section of the second support bar to the bed, and (b) an open position in which the clamping knob assembly is disconnected and the bed is disposed away from the second horizontal support section of the second support bar thereby rendering the roof or top accessible for removal or retraction.
The two first vertical mounting sections and the two second vertical mounting sections are bent to position the utility rack with respect to the vehicle. A gas spring assembly is attached to the bed and to the first support bar for facilitating pivot of the bed between the open and closed positions. An additional and optional component of the utility rack is at least one floodlight mounted to the second support bar. Of import is that the utility rack nowhere contacts the roof or top of the vehicle but permits removal or retraction of the roof or top when the bed is in the open position.
It is to be understood that both the foregoing general description and the following detailed description are exemplary, but are not restrictive, of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The invention is best understood from the following detailed description when read in connection with the accompanying drawing. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawing are the following figures:
FIG. 1 is a side view of one embodiment of the utility rack of the present invention mounted to a vehicle showing how the utility rack is releasably attached to the front support bar and pivots about the rear support bar;
FIG. 2 is a front view of the utility rack shown in FIG. 1, highlighting the optional floodlights, mounted on a vehicle according to the present invention;
FIG. 3 is a rear view of the utility rack shown in FIG. 1 mounted on a vehicle;
FIG. 4 is a front view of the front support bar of the vehicle utility rack according to the present invention;
FIG. 5 is a side view of the front support bar of the vehicle utility rack shown in FIG. 4;
FIG. 6 is a front view of one embodiment of the rear support bar of the vehicle utility rack according to the present invention;
FIG. 7 is a top view of the rear support bar shown in FIG. 6;
FIG. 8 is a side view of the rear support bar of the vehicle utility rack shown in FIG. 6;
FIG. 9 is an enlarged side view of one embodiment of the rear mounting assembly according to the present invention;
FIG. 10 is an enlarged view of one embodiment of the front mounting assembly according to the present invention;
FIG. 11 is an enlarged cross-section of one embodiment of the hinge mechanism according to the present invention;
FIG. 12 is an enlarged view of the gas spring and its related mounting brackets according to the present invention;
FIG. 13 is a side view of one embodiment, a clamping knob assembly, used to releasably attach the bed to the front support bar of the utility rack according to the present invention; and
FIG. 14 is a side view of another embodiment of the utility rack of the present invention mounted to a vehicle.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawing, in which like reference numbers refer to like elements throughout the various figures that comprise the drawing, FIG. 1 shows a utility rack 1 for a vehicle 100 , such as a SUV or an ATV, with a removable top or roof. The vehicle top can be a hard or a soft top and can be either entirely removable or retractable from a closed into an open position. The top may cover one or both of a passenger and a cargo compartment.
FIG. 1 is a side view of one embodiment of the utility rack 1 mounted to a vehicle 100 . The utility rack 1 has a front U-shaped support bar 10 . The front U-shaped support bar 10 has a horizontal support section 12 and two, mirror-image, left- and right-hand side, vertical mounting sections 14 and 16 . The vertical mounting sections 14 and 16 , of the front U-shaped support bar 10 , are attached to the vehicle 100 by front mounting plate assemblies 18 .
The utility rack 1 also has a rear U-shaped support bar 20 . The rear U-shaped support bar 20 has a horizontal support section 22 and two, mirror-image, left- and right-hand side, vertical mounting sections 24 and 26 .
The vertical mounting sections 24 and 26 , of the rear U-shaped support bar 20 , are attached to the vehicle 100 by rear mounting plate assemblies 28 . The front and rear U-shaped support bars 10 and 20 , respectively, support a bed 30 . The bed 30 is attached in a releasable fashion to the front horizontal support section 12 of the front U-shaped support bar 10 . Conventional hardware such as clamps, brackets, and snap-fittings may be used to releasably attach the bed 30 to the front horizontal support section 12 . The rear of the bed 30 is pivotally mounted to the rear horizontal support section 22 of the rear U-shaped support bar 20 .
FIG. 13 is a side view of one embodiment, a clamping knob assembly 90 , used to releasably attach the bed 30 to the front horizontal support section 12 of the utility rack 1 according to the present invention. The clamping knob assembly 90 has four components: a clamp knob 92 suitable for easy rotation by the user, a threaded rod 94 integral with the clamp knob 92 and rotated upon rotation of the clamp knob 92 , a locking wing nut 96 which engages the end of the threaded rod 94 and locks the clamping knob assembly 90 in position, and a threaded insert 98 . With the locking wing nut 96 removed, the threaded rod 94 passes through an opening provided in the bed 30 and engages the threaded insert 98 which is positioned in a corresponding opening in the front horizontal support section 12 . The user rotates the threaded rod 94 , by turning the clamp knob 92 , until the threaded rod 94 fully engages and partially protrudes from the threaded insert 98 . Application by the user of the locking wing nut 96 to the portion of the threaded rod 94 protruding from the threaded insert 98 locks the clamping knob assembly 90 in position and secures the bed 30 to the front horizontal support section 12 of the utility rack 1 . Removal by the user of the locking wing nut 96 allows removal of the threaded rod 94 from the threaded insert 98 in the front horizontal support section 12 and from the opening in the bed 30 and, therefore, releases the bed 30 from attachment to the front horizontal support section 12 .
A saddle 88 may be provided as a component of the utility rack 1 . As illustrated in FIG. 13, the saddle 88 has a flat front face and a semicircular portion. The semicircular portion is positioned between the bed 30 and the front horizontal support section 12 , and follows the contour of the bed 30 . The flat front face is positioned against the outside surfaces of the bed 30 and the front horizontal support section 12 . Thus, the saddle 88 can be used to align and space the bed 30 and the front horizontal support section 12 .
Returning to FIG. 1, the bed 30 is shown in two positions. In its first and closed position, the bed 30 is attached to the front horizontal support section 12 of the front U-shaped support bar 10 and sits horizontally over and a few inches above the roof of the vehicle 100 . In its second and open position, the bed 30 is detached from the front horizontal support section 12 of the front U-shaped support bar 10 and pivots upwardly away from the roof of the vehicle 100 . The user gains easy access to the roof of the vehicle when the bed 30 is in its open position. Moreover, the roof can be removed or retracted by the user as desired with the bed 30 in its open position and still attached to the vehicle 100 . This desirable attribute of the utility rack 1 is attained, in part, because no structure of the utility rack 1 is attached to or otherwise directly contacts the roof of the vehicle 100 .
A gas spring assembly 40 is attached to the rear vertical mounting sections 24 and 26 and to the bed 30 . The gas spring assembly 40 facilitates pivoting the bed 30 about the rear horizontal support section 22 of the rear U-shaped support bar 20 between the closed and open positions. Preferably, two gas assist shocks 42 are included in the gas spring assembly 40 . The size of the shocks 42 will depend upon the application (including the weight to be placed on the bed 30 ) and the preference of the user; a pair of shocks 42 each rated at about 200 pounds will often suffice. The shocks 42 are mounted to the utility rack 1 and are located on either side of the vehicle 100 . The bed 30 is supported by and pivotally mounted with a hinge 50 to the horizontal support section 22 of the rear U-shaped support bar 20 .
FIG. 12 is an enlarged view of the gas spring 40 and its related components according to the present invention. In the specific embodiment shown, the gas spring 40 includes a gas assist shock 42 on either end of which is provided a mounting bracket. Front mounting bracket 44 is adapted to be secured to the bed 30 ; rear mounting bracket 46 is adapted to be secured to one of the vertical mounting sections 24 and 26 of the rear U-shaped support bar 20 . The gas spring 40 allows the user to push the bed 30 upward, using the helpful force of the gas assist shocks 42 , toward the open position. Upon full extension of the gas assist shocks 42 , the bed 30 will reach, maintain, and essentially lock in a fully open position. The user pulls down on the bed 30 , against the force of the gas assist shocks 42 but using the help of gravity, to bring the bed 30 into its closed position. The bed 30 can then be affixed to the front horizontal support section 12 of the front U-shaped support bar 10 using the clamping knob assembly 90 . Of course, an electric motor (not shown) might be provided to assist the user with raising and lowering the bed 30 between its open and closed positions.
FIG. 2 is a front view of another embodiment of the utility rack 1 mounted on the vehicle 100 . FIG. 2 shows the front mounting plate assemblies 18 preferably mounted to existing holes in the side panel, without blocking the doors or other components, of the vehicle 100 . Conventional fasteners such as screws or bolts are inserted through holes in the front mounting plate assemblies 18 and through the corresponding holes that exist in the vehicle 100 . As noted above, the front mounting plate assemblies 18 are attached to the vertical mounting sections 14 and 16 of the front U-shaped support bar 10 .
Floodlights 60 may optionally be mounted to the front horizontal support section 12 of the front U-shaped support bar 10 . It may be desirable in some applications or for some users not to have any floodlights 60 mounted on the front horizontal support section 12 . In fact, some states do not permit floodlights 60 . Alternatively, as many floodlights 60 as desired may be mounted on the front horizontal support section 12 depending on the size of the individual floodlights 60 and the width of the vehicle 100 . Preferably, two to five floodlights 60 are mounted. Still more preferably, five floodlights 60 are mounted as illustrated in FIG. 2 . Floodlights 60 are typically off-road lights and may be provided with a remote control switch.
Because the floodlights 60 are mounted to the front horizontal support section 12 of the front U-shaped support bar 10 , the front horizontal support section 12 might also be called a “light bar.” It is important to note that the floodlights 60 and the front horizontal support section 12 , to which the floodlights 60 are mounted, are both disposed above all components (especially the window) of the vehicle 100 . Such disposition ensures that the utility rack 1 does not interfere with the normal operation of the vehicle 1 , which includes raising and lowering of the windshield as desired.
FIG. 3 is a rear view of the utility rack 1 mounted on the vehicle 100 according to the present invention. The rear view of FIG. 3 shows the rear U-shaped support bar 20 with the horizontal support section 22 connected to the vertical mounting sections 24 and 26 . Rear mounting plate assemblies 28 support the vertical mounting sections 24 and 26 . The rear mounting plate assemblies 28 are preferably adapted to be mounted to the existing bolt holes of the tail lights, without blocking the tail lights, spare tire, or other components, of the vehicle 100 . Additional holes may be formed in the vehicle 100 to accommodate the rear mounting plate assemblies 28 ; if formed, such additional holes are preferably sufficiently few that the rear mounting plate assemblies 28 can be attached to the vehicle 100 without substantial modification to the vehicle 100 . Conventional fasteners such as screws or bolts are inserted through holes in the rear mounting plate assemblies 28 and through the corresponding holes that exist in the vehicle 100 .
FIG. 4 is a front view of the front U-shaped support bar 10 of the vehicle utility rack 1 according to the present invention. FIG. 4 shows the horizontal support section 12 and the vertical mounting sections 14 and 16 . Also shown are the front mounting plate assemblies 18 attached to the vertical mounting sections 14 and 16 .
FIG. 5 is a side view of the front U-shaped support bar 10 of the vehicle utility rack 1 according to the present invention. The side view of FIG. 5 shows how, in this particular embodiment, the vertical mounting sections 14 and 16 are slightly bent. The bent shape of the vertical mounting sections 14 and 16 allows the horizontal support bar 12 to be separated from, supported on, and positioned best with respect to the vehicle 100 . The bent shape of the vertical mounting sections 14 and 16 also allows for the optional floodlights 60 to be mounted on the front horizontal support bar 12 in a suitable position with respect to the vehicle 100 .
FIG. 6 is a front view of the rear U-shaped support bar 20 of the vehicle utility rack 1 according to the present invention. The rear mounting plate assemblies 28 support the vertical mounting sections 24 and 26 . Illustrated on the rear mounting plate assemblies 28 are a series of openings 34 used to affix the utility rack 1 to the rear of the vehicle 100 . Attached to the vertical mounting sections 24 and 26 is the rear horizontal support section 22 . The rear horizontal support section 22 has apertures 32 which are adapted to connect the pivoting mechanism for the bed 30 .
FIG. 7 is a top view of the rear U-shaped support bar 20 of the vehicle utility rack 1 according to the present invention. FIG. 7 shows the rear mounting plate assemblies 28 , which support the vertical mounting sections 24 and 26 . This view also illustrates that the junction between the rear mounting plate assemblies 28 and the vehicle 100 , and the back edge of the rear horizontal support section 22 , lies in substantially the same vertical plane.
FIG. 8 is a side view of the rear U-shaped support bar 20 of the vehicle utility rack 1 according to the present invention. FIG. 8 shows the rear mounting plate assemblies 28 supporting the vertical mounting sections 24 and 26 attached to the rear horizontal support section 22 . The side view of FIG. 8 shows how, in this particular embodiment, the vertical mounting sections 24 and 26 are bent at two points to create a slight “S” shape. The bent shape of the vertical mounting sections 24 and 26 allows the horizontal support section 22 to be separated from, supported on, and positioned best with respect to the vehicle 100 .
FIG. 9 is an enlarged side view of an embodiment of the rear mounting plate assembly 28 according to the present invention. The rear mounting plate assembly 28 is adapted to attach to existing bolt holes of the tail lights 102 of the vehicle 100 . In the embodiment illustrated in FIG. 9, a few additional holes have been formed in the vehicle 100 (without substantial modification to the vehicle 100 ) and the rear mounting plate assembly 28 has three components: an outside mounting plate 70 , a top inside mounting plate 72 , and a bottom inside mounting plate 74 . The outside mounting plate 70 has a pair of flanges 76 , each forming a bore 78 that receives one of the vertical mounting sections 24 and 26 (as shown in FIGS. 6 - 8 ). Provided in the outside mounting plate 70 is a passage 80 (see FIG. 6) permitting the electrical conduit 104 of the tail light 102 to access the vehicle 100 . A plurality of conventional fasteners 82 are used to connect the three components of the rear mounting plate assembly 28 to each other and to the vehicle 100 .
FIG. 10 is an enlarged view of an embodiment of the front mounting plate assembly 18 according the present invention. The front mounting plate assembly 18 is adapted to attach to existing bolt holes in the vehicle 100 . In a preferred embodiment, the front mounting plate assembly 18 is designed to attach to existing bolt holes just below the front windshield hinge of the vehicle 100 . Thus, the utility rack 1 permits full operation of the windshield (e.g., lowering and raising). The front mounting plate assembly 18 includes one or more holes 84 positioned and configured to correspond with suitable holes in the vehicle 100 .
FIG. 11 is an enlarged cross-section of an embodiment of the hinge 50 which allows the bed 30 to pivot about the rear horizontal support section 22 of the rear U-shaped support bar 20 at the top of the vertical mounting sections 24 and 26 . The hinge 50 of FIG. 11 is adapted to be bolted, screwed, or otherwise affixed to both the bed 30 and the rear horizontal support section 22 . Alternatively, the hinge 50 may be an integral, continuous, monolithic part of the bed 30 and the rear horizontal support section 22 .
By allowing rotation between components, the hinge 50 allows the front of the bed 30 to be lifted from the front horizontal support section 12 of the front U-shaped support bar 10 . In this particular embodiment of the present invention, the bed 30 pivots on the rear horizontal support section 22 . In other embodiments, the bed 30 may pivot on the front horizontal support section 12 or on a side support bar. In any embodiment, the pivoting bed 30 will not impinge upon the removal of the hard or soft temporary top or roof of the vehicle 100 .
FIG. 14 is a side view of another embodiment of the utility rack 1 mounted to a vehicle 100 . In this embodiment of the utility rack 1 , one additional component is provided and one of the components illustrated in the embodiment of FIG. 1 has been modified. The additional component is a side stiffening bar 38 . Two side stiffening bars 38 may be provided, one on each side of the utility rack 1 . The side stiffening bars 38 are affixed to and extend between the front support bar 10 and the rear support bar 20 . Thus, the side stiffening bars 38 add rigidity and structural support to the utility rack 1 .
The modified component is the gas spring assembly 40 . As illustrated in FIG. 12, the gas spring assembly 40 has a front mounting bracket 44 secured to the bed 30 and a rear mounting bracket 46 secured to the rear support bar 20 . The inclusion of the side stiffening bars 38 in the embodiment of FIG. 14 allows the gas spring assemblies 40 to be attached to the side stiffening bars 38 rather than to the rear support bar 20 . Therefore, the gas spring assembly 40 does not need a rear mounting bracket 46 and none is shown in FIG. 14 . The side stiffening bars 38 thus function to mount the gas spring assemblies 40 .
The utility rack 1 of the present invention may be constructed of durable, lightweight material. Such material may include but is not limited to aluminum, steel, carbon fiber, composite, or other suitable material. The utility rack 1 may be made of a high-impact plastic, and may also be molded in part or in its entirety. Preferably the material has rust-resistant properties or is imparted with a rust-resistant coating. In one embodiment, the utility rack 1 is made of 1.5 inch diameter steel tubing that is welded for strength.
The present invention may be constructed as a unitary, monolithic, welded rack providing maximum strength and eliminating rattling from bolt-loosening present in the prior art. Alternatively, the utility rack 1 of the present invention may include separate components that may be bolted, threaded, or preferable welded together. This alternative allows the various components to be transported and installed more easily. It also offers other advantages: specifically, the light bar may be marketed and provided as an entirely stand-alone component. In either case, whether unitary or formed of separate components, the utility rack 1 of the present invention may be provided assembled on a new vehicle or provided as a separate kit suitable for retroactively upgrading a used vehicle.
Although illustrated and described above with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. For example, the figures depict rounded bars and illustrate the front and rear support bars configured in a U-shape; other cross sections and shapes may also be used. | A hinged utility rack disposed on and external to a vehicle having a temporary top or roof. The utility rack has a bed that supports objects especially for transportation. First and second support bars are attached to the vehicle and support the bed. The second support bar is releasably connected to the bed, supporting the bed when connected. A hinge pivotally connects the first support bar to the bed, enabling the bed to pivot about the first support bar. The bed pivots between (a) a closed position in which the bed covers the vehicle top and the second support bar is connected to the bed, and (b) an open position in which the second support bar is disconnected from the bed and the bed is disposed away from the second support bar thereby rendering the top accessible for removal or retraction. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to the cleaning or preparation of fruits and vegetables, especially that cleaning which requires the removal of a portion of the fruit or vegetable. More particularly, the present invention teaches a method for removing the calyxes from fruit, especially pulpy fruit including berries, during the harvesting or packing process.
BACKGROUND OF THE INVENTION
[0002] Strawberries are an important crop in many areas of the country. Most familiar to retail consumers are the one- or two-pint baskets of berries commonly found at grocers. This type of harvesting is characterized by the grower picking substantially “perfect” berries just before they are completely ripe. Such market harvest is typically performed so that the part of the berry immediately adjacent to the calyx, hereinafter the “shoulder”, is green, or white in color. Final ripening of the berry occurs in the basket during transport to the market. In addition to this “market” sale of harvested berries, strawberries are commonly harvested and processed for at least two other uses.
[0003] A first alternative use for strawberries is the sale of berries, typically including bruised or damaged fruit, to packers for juice purposes. Strawberry juice is a product which is widely used in the manufacture of jams, preserves, strawberry filling, and other manufactured items requiring strawberry taste and sugar but which do not require whole or partial berry fruit. As might be expected, the sale of strawberries in this form is the least profitable of any of the harvest methodologies. Such use does however retain to the grower some profit for his efforts.
[0004] Berries are also sold to packers and other processors as substantially intact fruit, less those portions of the fruit not generally deemed edible. This is done by removing the calyxes from the fruit. Calyx removal can be accomplished either in packing houses or in the field by the harvest workers, and is typically accomplished by nothing more sophisticated than the removal of the calyx from the top of the berry with the worker's thumb or thumbnail. While this harvesting method results in the sale of fruit having an increased market value over berry juice, the methodology whereby calyxes are removed during processing or harvest results in several deleterious factors. Again, this produce item is sold by weight. Accordingly, it is economically important to the grower that the removal of the strawberry calyx removes a minimal amount of fruit by weight, and also does minimal damage to the berry whereby juice leakage occurs, again causing the grower weight, and thus profit, loss. This form of packaging is therefor typically performed on completely ripe fruit, as opposed to the previously discussed ripening fruit.
[0005] A first problem with the simple manual removal of calyxes from berries is the attendant and inherent lack of sanitation in the process. A second problem with this methodology is that it is inherently wasteful. The workers typically crush or destroy a significant part of each individual ripe berry as they remove the calyx utilizing this crude methodology. Moreover, the simple crushing or pinching of the upper part of the berry not only tends to remove more of the berry, and hence its value, than would be the case were the berry cleaned in a more orderly fashion, but the crushing of the upper part of the berry results in further loss of juice and increased spoilability of the harvested crop. Indeed, a crushed berry is very difficult, if not impossible, to effectively wash and sanitize prior to packaging. Finally, to enable the previously discussed manual means of calyx removal, the grower must allow the berries to remain on the stem for an additional 4-8 days longer than berries harvested for market. This means that the decision to make the former type of harvest is irrevocable.
[0006] In order to economically process berries by removing the calyx and a portion of the upper part of the berry so that the berries can be sold in their cleaned state, either the previously discussed crude manual methodology is employed, or the berries are removed to packing houses where workers clean them manually using knives and cutting boards. This latter methodology presents the disadvantage of handling each berry twice and imparts an additional manpower expense to the harvest process. Further, this subjects the berries to additional damage due to the additional handling.
[0007] What is needed is a methodology, and an apparatus to perform the methodology, which enables workers, particularly field workers, to rapidly and efficiently clean the berries as they are harvested. The methodology should enable the rapid removal of calyxes and a portion of the upper strawberry leaving the balance of the berry substantially uncrushed, or with reduced crushing, and with a neat sanitary cut as opposed to a crudely crushed upper surface, which leaks juice and pulp, thereby minimizing fruit loss. The methodology should enable and facilitate sanitation of the apparatus in field conditions. The apparatus should be safe for workers to use and minimize danger to the workers' hands while processing the berries under the extreme time pressures occasioned by the berry harvest. The methodology should adapt itself to current berry or fruit picking technology and ideally, form an adjunct thereto. Finally the apparatus to perfect the method should be capable of economic manufacture and distribution.
SUMMARY OF THE INVENTION
[0008] The present invention teaches the use of a novel aperture knife adapted for use during the harvest. The aperture knife of the present invention is a generally planar structure defining at least one aperture therethrough for the neat, sanitary separation of the calyx and a small portion of the upper part of the fruit body from the balance of the fruit body itself. The aperture knife of the present invention is attachable to a variety of agricultural implements and containers utilizing attachment methodologies suitable for the equipment or containers at hand.
[0009] In use the worker takes a harvested berry and places it on the upper surface of the aperture knife of the present invention. The worker then impels the berry towards the aperture which, being generally sharpened, cleanly removes the calyx and a portion of the upper berry from the fruit body itself. As the worker continues to impel the berry towards, the calyx drops under the knife through the aperture and as the berry is impelled off the knife, it is collected in a box, bin or other collection device. Where the cleaning is performed in the field during the harvest, this methodology has the further advantage of leaving the calyxes in the field where they can be turned into compost for the next planting.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0010] For fuller understanding of the present invention, reference is made to the accompanying drawing in the following Detailed Description Of The Invention. In the drawing:
[0011] [0011]FIG. 1 is a plan view of the aperture knife of the present invention.
[0012] [0012]FIG. 2 is an obverse plan view of the attachment device of the present invention.
[0013] [0013]FIG. 3 is a transverse section through several of the elements of the aperture knife of the present invention.
[0014] [0014]FIG. 4 is a section through the knife aperture showing the relationship of the knife edge to the elevated portion of the aperture knife.
[0015] [0015]FIG. 5 is a section through aperture knife 100 in use showing the methodology of that use.
[0016] [0016]FIG. 6 is a prior art representation of a picking cart to which aperture knife 1 of the present invention is rendered attachable.
[0017] [0017]FIG. 7 is a representation of a picking cart having an aperture knife according to the principles of the present invention attached thereto.
[0018] [0018]FIG. 8 is an elevation through the knife and elevated section of the aperture knife.
[0019] [0019]FIG. 9 is a plan view of the blade region according to a second preferred embodiment of the present invention.
[0020] [0020]FIG. 10 is a plan view of a blade element for operative combination with the blade region of the second preferred embodiment.
[0021] [0021]FIG. 11 is a side view of the blade element for operative combination with the blade region of the second preferred embodiment.
[0022] [0022]FIG. 12 is a plan view of second preferred embodiment of the present invention.
[0023] [0023]FIG. 13 is a plan view of second preferred embodiment of the present invention, implementing a removable version of the blade element.
[0024] [0024]FIG. 14 is a front view of second preferred embodiment of the present invention, implementing a removable version of the blade element.
[0025] Reference numbers refer to the same or equivalent parts of the invention throughout the several figures of the drawing.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring now to FIG. 1, an aperture knife constructed according to the principles of the present invention is shown. In a first preferred embodiment of the present invention, aperture knife 1 takes the form of a generally planar structure having a blade region 10 in operative combination with an attachment device 20 . Attachment device 20 is for attaching aperture knife 1 to a commonly encountered article of agricultural equipage or containment as will be described below.
[0027] Blade surface 10 is formed to define an aperture, 12 , and an edge portion 14 . In use it is contemplated that the portion of blade 10 here marked P will be proximal, or closest to the worker utilizing the knife. In like fashion, it is contemplated that the portion of the knife indicated by the letter D will generally be furthest from the worker. It is in this orientation that the utilization of this preferred embodiment of the present invention is explained. Distal to edge portion 14 and arising therefrom is a generally elevated region 16 . It is across this upper surface that the bulk of the fruit body passes into a container after having been cleaned. Alternative knife arrangements including one whereby the worker first starts the fruit at the distal portion of the knife impelling it towards the proximal portion of the knife as well as lateral or other configurations are also contemplated by the principles of the present invention.
[0028] Having further reference to FIG. 1, the first preferred embodiment is further described as follows: aperture knife 1 is formed with blade portion 10 defining a generally proximal planar region 18 where the worker first places the berry in a substantially inverted alignment. Also formed on blade portion 10 is an elevated section 16 . In a first preferred embodiment of the present invention elevated portion 16 takes the form of a longitudinally raised section in operative combination with an aperture 12 which defines an edge region 14 . Edge region 14 may be sharpened according to the degree of sharpness desired, as shown. Alternatively, edge region 14 may be formed by the fabrication of edge knife 1 from sufficiently thin material that the cut edge of the material is sufficiently sharp to sever the calyx from the fruit body. Edge region 14 in operative combination with raised portion 16 provides for an inverted V-shaped knife which engages a portion of the fruit thereby severing it from the fruit body, discussed in detail herebelow.
[0029] Blade portion 10 is in operative combination with an attachment device for attaching the aperture knife to another structure. This attachment device enables a worker to remove the calyx from a fruit item, particularly a strawberry, in one motion utilizing only one hand. This then enables, for the first time, a means of cleanly severing the calyx from the fruit in a manner sufficiently efficient to enable the commercial viability of the process. It should be noted that previous manual methods either resulted in excessive fruit, and hence profit, loss during calyx removal, or were performed by workers utilizing two hands and a knife and a cutting board. This latter methodology is both inefficient and expensive.
[0030] Having continuing reference to FIG. 1, and with further reference to FIGS. 2, 6, and 7 , one attachment methodology whereby the aperture knife of the present invention is rendered attachable to a commonly found item of berry harvesting equipment is discussed. Referring now to FIG. 6, a prior art strawberry picking cart, 50 , is shown. Picking cart 50 comprises a wheeled structure having a means thereon for receiving a picking box or other container, not shown. In use a picking box is set into picking cart 50 and the worker manually moves the cart and box along the berry row during the harvesting process. This the worker is enabled to do by means of wheel 52 as well as handle 54 . Handle 54 generally takes the form of an elevated regular trapezoid form and is, like the balance of the cart, often made of tubing, pipe, wire or the like. To removably attach the aperture knife of the present invention to picking cart 50 , attachment device 20 takes the form of a generally matching trapezoidal angle and further defines a pair of recursively formed wings 22 and 22 ′. To attach aperture knife 1 to picking cart 50 , as shown in FIG. 7, wings 22 and 22 ′ are positioned over handle 54 of picking cart 50 and the device lowered into position where it is received onto handle 54 and retained in position by gravity and friction. As is shown in FIG. 7, this configuration places aperture knife 1 with the proximal end of aperture knife 1 closest to the worker standing near the handle 54 , and the distal end of aperture knife 1 at or near picking box 60 . Moreover, any such reversible attachment methodology enables the rapid cleaning and disinfection of the device in the field by the facile removal of the knife and subsequent sterilization. Sterilization may be performed by any sterilizing means known to those having ordinary skill in the art, including but not necessarily limited to: immersion in chlorine, iodophor or the like; the application of heat; boiling; soap; or other known cleaning or sterilizing means. Finally, the principles of the present invention contemplate attaching the aperture knife to the worker or his clothing by straps, hook-and-loop tape, clips, snaps, zippers, patent fasteners, or other attachment methodologies known to those having ordinary skill in the art.
[0031] Referring now to FIGS. 3, 4, and 5 , the operation of aperture knife 1 is explained. A cross section, A-A′, as shown in FIG. 1, is detailed in FIG. 4. Study of this figure reveals that the formation of aperture 12 , not shown, results in a transition of generally planar section 18 to elevated section 16 . This transition is formed along knife edge 14 which serves to clean the berries. FIG. 3, a cutaway section through aperture knife 1 , details the relationship of the several sections of the knife.
[0032] Referring now to FIGS. 8 and 3, the elevation of aperture 12 with respect to planar region 18 and elevated region 16 is shown. In a first preferred embodiment, substantially as shown in FIG. 8, planar region 18 extends distally to form tongue 15 . The altitude of tongue 15 with respect to elevated region 16 defines the vertical extent of aperture 12 . This determines the amount of calyx and berry shoulder removed during operation of the device.
[0033] A further alternative contemplates adjusting the angle of tongue 15 with respect tot planar section 18 , thereby forming tongue 15 ′ as shown in FIG. 3. This embodiment may obviate the need to actually form elevated region 16 is some applications.
[0034] Referring now to FIG. 5, the method of using aperture knife 1 is shown. A worker places berry 100 in an inverted manner at planar section 18 , which it will be recalled in this embodiment, is generally closest or proximal to the worker. Grasping berry 100 with one hand, the worker urges or impels berry 100 towards elevated section 16 and knife edge 14 . As the berry 100 contacts knife edge 14 , the two arms, not shown, of knife edge 14 simultaneously urge the berry 100 into generally central alignment with respect to knife edge 14 . Referring now to FIG. 1, it will be appreciated that knife edge 14 is, in this embodiment, a generally V-shaped structure formed by the creation of a generally V-shaped aperture 12 . Accordingly, knife edge 14 further comprises edges 14 ′ and 14 ″. It has been found that the use of converging knife edges 14 ′ and 14 ″ enables the rapid accurate placement and cutting of berries with the apparatus. Alternative knife geometries, including arcuate edges, straight edges, and polygonal edges may, with equal facility, be implemented. In implementing these differing knife geometries, alternative tongue geometries may be formed. Such tongue geometries include forms corresponding to the knife, as shown herein, as well as tongue geometries differing from the knife geometry. An example of this latter embodiment would be the use of an arcuate tongue with an angled blade.
[0035] Having continued reference to FIG. 5, as berry 100 is urged in the direction indicated, the converging nature of knife edges 14 ′ and 14 ″ engages the shoulder of the berry nearest its calyx 102 . As the berry 100 is continually urged along aperture knife 1 , the cut through either side of the berry is joined and completed, thereby freeing calyx 102 from berry 100 . A continuation of the worker's motion urges berry 100 towards a collection device, for instance a container, not shown.
[0036] A first preferred embodiment of the present invention is formed from corrosion resistant sheet metal, formed substantially as discussed. This formation may be by means of stamping, welding, casting, or other metal fabrication means well known to those having ordinary skill in the art. Alternatively, the present invention may, with equal facility, be implemented utilizing a number of alternative materials including but not necessarily limited to plastics, fiber reinforced plastics, ceramics, or composites or combinations of the foregoing.
[0037] The first preferred embodiment of the present invention is preferably formed as a single piece. One alternative embodiment contemplated by the principles of the present invention is the formation of the aperture knife thereof by two or more parts. This “two-part” embodiment may be formed with several methodologies, as shown in FIGS. 9 through 14.
[0038] Having reference now to FIG. 9, the blade portion 10 of aperture knife 1 is shown. In this embodiment, aperture 12 ′ is formed substantially as shown, aperture 12 ′ further defining tongue 15 . In operative combination with blade portion 10 is blade element 60 shown in FIG. 10. Having reference to that figure, blade element 10 includes an elevated portion 64 similar to elevated section 16 shown in FIG. 8. Additionally, blade element 60 comprises a substantially planar lip 61 extending around one or more edges of elevated section 64 . Optionally, the detent receiver 73 would be formed in one or more portions of lip 61 . Detent receiver 73 will be explained below. A side view of blade element 60 is shown in FIG. 11.
[0039] Blade element 60 may be attached to blade portion 10 in substantially any manner known to those having ordinary skill in the art. In one version of this embodiment, blade element 60 is positioned over aperture 12 ′, as shown. After placement of blade element 60 over aperture 12 ′ blade element 60 is permanently affixed to blade portion 10 by means of welding lip 61 at one or more places around its periphery, as at 65 . Alternative permanent attachment methodologies, including but not necessarily limited to brazing, soldering, riveting, spot welding, impulse welding, and the like may, with equal facility, be implemented.
[0040] Another version of this embodiment contemplates that blade element 60 may be rendered removable from blade portion 10 for means of cleaning, sharpening, or other maintenance functions. In means of implementing this embodiment, one or more raised receivers, 70 , is formed in blade portion 1 . In this embodiment blade element 60 is slidably received into receivers 70 , and is retained in place by one or more detents 71 formed in receiver 70 which is further received into detent receiver 73 shown in FIG. 10. In this manner, blade element 60 is retained in position over aperture 12 ′ yet is rendered removable for the previously discussed maintenance functions. Again, alternative removable attachment methodologies may, with equal facility, be implemented to perform this function. These methodologies include, but are again not necessarily limited to: screw fasteners; bolts and nuts; patent fasteners such as Dzus® fasteners; pins, including cotter pins; clips; and the like. A front view of this embodiment is shown at FIG. 14.
[0041] The attachment device 20 previously discussed details one attachment methodology contemplated by the present invention. It will again be obvious to those having ordinary skill in the art that alternative attachment methodologies whereby the aperture knife of the present invention is rendered attachable, particularly reversibly attachable, to an article of agricultural equipment, processing equipment, or the like may with equal facility be implemented. These attachment methodologies include, but are again not necessarily limited to: screw fasteners and the like, rivets, patent fasteners such as Dzus® fasteners, brackets, clamps, patent fasteners, hook-and-loop tape, adhesives, weldments, and other attaching methodologies known to those having ordinary skill in the art.
[0042] The present invention has been particularly shown and described with respect to certain preferred embodiments of features thereof. However, it should be readily apparent to those of ordinary skill in the art that various changes and modifications in form and detail may be made without departing from the spirit and scope of the invention as set forth in the appended claims. In particular, the use of the present invention with alternative attachment methodologies, knife geometries, aperture geometries, materials, and the like are specifically contemplated by the principles of the present invention. The invention disclosed herein may be practiced without any element which is not specifically disclosed herein. | Method for the rapid cleaning of produce with minimal loss, and apparatus to perform the method. The cleaning method taught in the present application enables the rapid cleaning of produce by removing an extraneous portion therefrom, by separating the extraneous portion from the body of the produce, and by urging the cleaned produce towards a collection device. These steps are attainable, using the principles of the present invention, by a working using only one motion and one hand. To perform the method, a novel aperture knife is taught which, rendered attachable to an agricultural processing implement by an integral attachment device, enables one-handed operation by a user. The knife includes a generally planar knife body in operative combination with an elevated blade which not only enables the severing of the extraneous portion from the produce body, but separates the extraneous portion therefrom, and guides the cleaned produce body towards a collection device, for instance a picking box. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of obtaining a menthol product by recrystallization from crude natural menthol, to the recrystallized menthol produce per se and the use of the recrystallied menthol produce in foods, beverages or tobacco.
2. Prior Art Relating to the Disclosure
Menthol has long been used for a flavorant in foods, beverages and tobacco. Menthol is obtained from both synthetic and natural sources. The menthol obtained from natural sources is generally purified by freeze recrystallization from solutions of the crude product. It has been thought that the larger the crystals obtained, the more pure the menthol obtained. It is known that there are eight possible isomers of menthol, six of which exist in nature. Two sets of four isomers of menthol have equal and opposite optical rotation. The natural menthol, generally imported from Brazil, Taiwan or Japan, when incorporated in beverages, foods or tobacco, gives a cooling sensation in the mouth of the user of the product incorporating the menthol; however, the cooling effect carries with it the medicinal taste of menthol.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide a menthol product recrystallized from natural menthol crystals which, when incorporated in foods, beverages and tobacco, creates a lingering cool sensation in the mouth of the user of the food, beverage or tobacco with little or no detection of the menthol taste. The recrystallized menthol product differs in its properties from natural menthol in (1) organoleptic qualities (odor and taste), (2) density of the crystalline mass, (3) crystal structure, size and shape, (4) solubility, and (5) gravity filtration rate.
It is a further object of this invention to provide a method for obtaining a menthol product having the previously described properties by dissolving natural menthol crystals in an alcohol-water solution, allowing phase separation and recrystallizing the menthol product from the phase containing liquid menthol.
It is a further object of this invention to provide a method of obtaining a menthol product having the previously described properties wherein recrystallization is carried out by suspending a glass rod or synthetic plastic-coated rod in the phase of the alcohol-water solution containing the liquid menthol, with the lower end of the rod at the interface between the two phases.
It is a further object of this invention to provide a menthol product creating a lingering cooling sensation in the mouth of the user with little or no accompanying menthol taste.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Crude natural menthol crystals, such as Brazilian Arvensis menthol crystals or menthol crystals from other sources, such as Japan and Taiwan, are pulverized and dissolved in an alcohol-water solution. The alcohol used is preferably ethanol. The ratio of alcohol to water may vary from 20-40% by volume alcohol, but preferably about 25% by volume alcohol and 75% water.
The amount of menthol dissolved in the alcohol-water solution is not particularly critical and may range from a weight ratio of menthol to alcohol-water solution of from 1:1 to 1:5. Some degree of warming may be necessary to effect dissolution of the natural menthol crystals in the alcohol-water solution. The menthol is dissolved with agitation and gives a milky appearing emulsion which is allowed to stand, preferably at ambient temperature (18°-25° C.), until phase separation occurs. Two phases form: an upper phase, which is clear and water-like and which contains liquid menthol and alcohol, and a lower phase, milky in appearance and containing primarily water along with alcohol, small amounts of dissolved menthol and residual impurities.
The menthol product which is the subject of this invention is recrystallized from the upper phase, preferably by suspending a rod in the upper phase with the lower end of the rod touching the interface between the upper and lower phases but not entering the lower phase. Recrystallization is best carried out in a clear glass vessel using a glass rod or rod of other material coated with synthetic resin, such as polyethylene or polypropylene. The temperature at which recrystallization is carried out appears to be a determining factor in the type and quantity of crystals obtained. The recrystallization temperature is preferably around ambient, i.e., 18°-25° C., preferably about 22° C.
After suspension of the rod in the upper phase of the alcohol-water solution, crystallization begins and is evident in two different places: (1) on the side wall of the container above the liquid level, generally on the side of the container or vessel subjected to sunlight, and (2) simultaneously on the suspended rod above the liquid level. The majority of the crystallization occurs on the rod and the crystals do not contact any portion of the liquid in most instances. The time necessary for complete crystallization varies but is generally around 24 hours. After about 8-12 hours, the crystals formed on the rod and side walls of the vessel are generally removed to allow formation of additional crystals. During crystallization, there appears to be a very marked phototropic effect as crystallization occurs on the side walls of the container subjected to sunlight. When the container is turned, the site of crystallization changes to orient itself to the direction of the sunlight.
The menthol crystals recovered by the recrystallization process differ markedly from the starting natural menthol crystals. The crystal structure of the recrystallized product is vastly different in shape, type and size from the original raw material. The starting crystals are generally large, needle-like crystals, whereas the crystals obtained by the process outlined above are less than 1/32 inch in diameter and almost amorphous in nature. The organoleptic qualities of the recrystallized menthol product are readily distinguishable from the starting menthol crystals in both odor and taste. The solubility of the recrystallized menthol crystals differs from that of the starting menthol crystals in that they are more difficult to solubilize. The density of the recrystallized menthol is less than the density of the starting crystals. The recrystallized product described floats in a refined coconut oil solvent while the starting crystals sink. It was also noted that when re-solution was attempted, a considerable difference in gravity filtration rate was observed in the recrystallized menthol compared to the gravity filtration rate of the starting menthol crystals using identical solvent systems, each containing the same concentration of menthol. It is not known to what the attribute the difference in properties in the product obtained by recrystallization and those of the starting menthol crystals. The recrystallized product may be a pure form of menthol or contain a different ratio of menthol isomers.
It was found that when the recrystallized menthol product was incorporated in beverages, such as tea, chocolate, soft drinks, etc., in relatively small amounts, it created a lingering cool sensation in the mouth of the user lasting as long as 20-30 minutes with little or no taste of menthol. The recrystallized product can be used at such a minimal level that the menthol taste cannot be detected and yet still achieve the lingering cool sensation.
The following examples are illustrative of the invention but are not intended to be limiting in any way.
EXAMPLE I
200 units by weight of crude, natural, Brazilian Arvensis menthol crystals were dissolved in a clear glass beaker containing 500 units by weight of an ethyl alchol-water solution containing 25% by volume of 95% SDA N0. 3A ethyl alcohol in distilled water. The solution was warmed slightly, with agitation, to thoroughly dissolve and mix the crystals to form a fast-breaking, milky appearing emulsion.
The solution was allowed to stand at ambient temperature (about 22° C.) until separation of the phases occurred. The upper phase was crystal clear and contained liquid menthol and alcohol. The lower phase was milky in appearance and contained primarily water with some alcohol and small amounts of dissolved menthol and residual impurities.
A polypropylene-coated steel rod was vertically suspended in the upper phase. The rod was lowered into the upper phase until its lower end touched the interface between the upper and lower phases. In less than 1 hour, crystallization began and was evident in two places: (1) on the side wall of the glass beaker above the liquid level and on the side of the beaker subjected to natural sunlight, and (2) on the polypropylene-coated rod above the liquid level. The majority of the crystallization occurred on the rod. No crystals were in contact with any portion of the liquid, in most instances.
The crystal structure of the recrystallized menthol product was vastly different in shape, type and size from the original starting material, and its organoleptic qualities, i.e., odor and taste, were readily distinguishable from the starting natural menthol crystals.
EXAMPLE II
Recrystallization was attempted as in Example I using, however, synthetic menthol crystals. It was found that the use of any portion of synthetic crystals retarded or completely prevented recrystallization.
It was also found that rapid or moderately rapid lowering of temperature during recrystallization prevented recrystallization into the crystalline menthol product described.
Recrystallization was attempted in a stainless steel vessel. Very little recrystallization was obtained and the recrystallized menthol was of poor quality.
The alcohol-water solvent of Example I was used for a second recrystallization. A recrystallized product was obtained but was not the same in terms of odor and taste as that obtained by the first recrystallization.
The menthol product of the first recrystallization was subjected to a second recrystallization to see if further refinement would produce a still more desirable product. This was not the case.
For reasons not understood, the desired cooling sensation obtained with the recrystallized menthol product is not as definite if any portion of the crystals is recovered from the liquid phase.
Two samples were made up for comparison on sensitive chromatographic equipment. One sample contained 30% by volume of crude, natural, Brazilian Arvensis menthol crystals dissolved in a refined coconut oil. A second sample contained 30% by volume of the menthol crystals described herein recrystallized from the Arvensis menthol crystals and dissolved in the same refined coconut oil. Both solutions were run on a gas chromatograph. The results indicated that both solutions contained two minor contaminants which eluted immediately ahead of the main menthol peak using a Silar 10C column for analysis. The concentration of these minor contaminants was less than 0.1% of the menthol content of the samples. A significant variation in the menthol content of the two samples was observed, however. In fact, the two samples contained the same amount of menthol and it is believed that the difference in menthol content detected by the gas chromatographic analysis is indicative of a change in the isomeric relationship of the various isomers of menthol. It is believed that the recrystallization process not only results in a clean product but also results in an isomeric rearrangement of menthol isomers which gives a relative ratio of isomers of uniqueness which results in the cool, clean taste sensation and the lingering cool sensation.
The recrystallized menthol product dissolved in refined coconut oil solvent may be applied to tobacco by spray deposition or other suitable process or incorporated into foodstuffs, such as candy. For incorporation in beverages, such as, for example, carbonated beverages, the menthol dissolved in the coconut oil solvent is placed in an emulsion, such as water-sorbitol-dispensing agent emulsion, and relatively small amounts of the emulsion (0.1 cc. emulsion in 10 oz. beverage, the emulsion containing about 6% menthol product) incorporated into the beverage. The recrystallized menthol product of this invention has a particular advantage when incorporated into artificially sweetened beverages in that the cool, clean taste covers the aftertaste generally associated with artificial sweeteners. | A recrystallized menthol product derived from crude natural menthol is described for incorporation into foods, beverages and tobacco in amounts sufficient to create a lingering cool sensation in the mouth of the user of the food, beverage or tobacco with little or no taste of menthol. The recrystallized menthol product is recrystallized from an ethanol-water solution of crude natural menthol under specific conditions. | 2 |
BACKGROUND OF THE INVENTION
Among the problems which have existed in the area of oil recovery, has been that of extracting, from a particular oil well, or well within a particular field, a satisfactory percentage of the total amount of the oil and gas within the particular petroleum reservoir.
This problem arises from the fact that, among the presently existing state of the art petroleum methods, none of said methods, which have proven to be otherwise practical, have produced an effective yield capability of more than 50 percent of the oil originally in place. The percentage of recovery which is generally obtainable will depend on such factors as: (1) the physical nature of both the reservoir rock and the oil itself; (2) the care exercised in completing and producing a particular well; and (3) the rate of oil and gas production from the field or reservoir as a whole.
Accordingly, it may be readily appreciated that vast quantities of valuable oil reserves have proven to be inaccessible by reason of various geological and technical factors. Alternatively, even where existent technology has proven adequate, the cost of such technology has proven to be unacceptable.
The prior art has of course witnessed various approaches which have been attempted in order to increase the recovery efficiency of existing oil wells.
For example, U.S. Pat. No. 3,103,975 (1963) entitled Communication Between Wells, held by A. W. Hanson, discloses a general technique directed to the utilization of an electrolyte in order to provide subterranean formations with an electro-chemical treatment which will improve the electrical communication within the various interstices which exist within a normal oil-bearing sedimentary stratum. Through the increase of such electrical communication, generally known as electrical conductivity, a flow of energy can be generated which will have the desired effect of enlarging the area of fracture and, thereby, the effective well or reservoir radius of the recovery area. Said patent to Hanson represents an interesting theoretical approach whose promise has not, as yet, been fully realized.
Also, of pertinence in the prior art in U.S. Pat. No. 3,106,244 (1963), entitled Process for Producing Oil Shale in Situ by Electro-carbonization, held by E. W. Parker. Said patent is representative of on-going technical efforts which have been exerted in the area of extracting oil from shale deposits through the appropriate application of electrical energy. As such, said patent represents another step in the development of the technology which has led to the present invention effort.
The use of electrical energy as a thermal source within petroleum strata is discussed in U.S. Pat. No. 3,149,672 (1964), entitled Method and Apparatus for Electrical Heating of Oil-Bearing Formations, held by J. Orkiszewski et al. An allied disclosure appears in U.S. Pat. No. 3,862,662, entitled Method and Apparatus for Electrical Heating of Hydro-Carbonaceous Formations, held by L. R. Kern.
Finally, and of close pertinence to the present inventive method, are U.S. Pat. Nos. 3,169,577 (1965) and 3,236,304 (1966), both held by E. Sarapuu. The first of said patents relates to the electro-linking of two wells through the use of impulse voltages on the order of 150 kilovolts. The second of said patents relates to a method for the electrofracing of oil sand formations through perforated casings.
The present inventive method may be viewed as a natural and necessary advancement of the above original but rudimentary methods proposed by the above inventors.
SUMMARY OF THE INVENTION
The present invention can be viewed as an effort to exploit what is believed to be the general susceptibility of reservoir rock to electrical energy when modulated and configurated in such a manner so as to utilize the particular physical and chemical characteristics of oil-bearing rock such as illustrated in FIG. 2.
While a wide variety of effects of electrical energy upon reservoir strata are believed to occur, most of such effects appear to be definable in terms of (1) heating effects and (2) shock effects.
The present invention seeks to utilize said heating effects in order to increase the fluidity of, and pressure upon, the oil existent in sedimentary strata in proximity to the electrical probes utilized in the present inventive method. That is, through an increase in the fluidity of and pressure upon oil trapped within cavities of limestone, sandstone, shale or other such oil-bearing formations, the probability of, through any one of a variety of electrical and physical mechanisms, release of said trapped oil will clearly increase, thereby enhancing the recovery efficiency of a given well or well system.
With regard to the anticipated electrical and physical shock effects of the present method, it is believed that oil reservoirs and, in particular, sandstone, shale and limestone reservoirs will prove to be highly susceptible to shock waves and, therefore, will create a degree of electrofracing and physical fracturing which will increase the amount of otherwise trapped oil that will be obtainable through the openings up of new paths to adjacent reservoirs.
In general, said above-described heating and shock effects will serve to greatly increase the geo-capillary flow of petroleum reserves within a given well system, and between wells.
In terms of formal objectives, the present invention may be viewed as having an object of providing a means for electrically linking one oil well to a second oil well, through an oil-bearing geological formation, in such a manner as to create a series of electrical, thermal and physical shocks adjacent to and between electrodes utilized at the bottom of said wells, thereby transmitting sufficient energy in order to cause fracturing in the vicinity of the well, and between wells, by means of electrical and physical impulses associated with discharged electrical energy.
It is a further object of the present invention to provide an electrical linking method between electrodes within an oil-bearing stratum by providing methods and means, at low initial cost, of light-weight equipment, powered by a portable electric generator or power line source having controllable output voltage, selectable frequency of pulsing and pulse width, and sufficiently high peak power output in order to obtain desired electrical, thermal and physical shock effects.
Other and further objects will be coming evident from the hereinafter set forth drawings and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional schematic view of an injection and recovery well provided with the method of the present inventive system.
FIG. 2 is a cross-sectional schematic view of a representative region of oil-bearing strata.
FIG. 3 is a system block diagram of the electrical discharge system.
FIG. 4 is a schematic diagram of a parallel charging circuit for use in association with the circuit of FIG. 3.
FIG. 5 is a schematic diagram of a series-mode discharge actuator for use in association with the circuit of FIG. 3.
FIG. 6 is a schematic diagram of one embodiment of a shut-down circuit for a series-string of capacitors.
FIG. 7 is a schematic diagram of an alternate embodiment of the circuit in FIG. 6.
FIG. 8 is a schematic diagram of an auxiliary heating-mode circuit.
FIG. 9 is a schematic view of a master controller for the circuit of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
It is to be borne in mind that the present petroleum recovery is intended to use existing non-producing or low production wells. Thus, no finding or drilling costs will be involved. In order to stimulate production, it is necessary to provide thermal input, subterranean electrical and physical shock, as well as electro-thermal or chemical charring or coking of the semi-solid hydrocarbon structure in order to increase conductivity, or to reduce its reciprocal, resistivity, in those areas where unrecovered oil may exist. For example, with reference to FIG. 2, one may note the existence of numerous pockets or pools of unrecovered oil. A heavy current flow over a carbonaceous path will, it is believed, also cause heat and steam fracturing or shattering of the sedimentary rock formations, leading to an increase in effective well and reservoir radius. Further, it may cause rock burst (expansion of connate water in heated rocks under stress and/or release of pressure on rocks under stress) by adjacent fracturing thereby providing new paths for the flow of newly freed oil.
The present process or system of oil recovery requires a minimum of two existing wells: an injection well 10 and a recovery well 12. See FIG. 1. In each well, an insulated high voltage cable 14 is clamped to a steel tubing 16 within the well casing 18, using stand-off insulating clamps in order to support and insulate the cable to the well bottom.
A heavy electrical conductor 20, from inside the insulated cable, is attached to a ground electrode 22 driven several feet down into the fragmented or sedimentary rocks 24 beneath each well. It is noted that, where possible, the electrodes 22 and 26 should be directed toward each other, thereby increasing the probability of completing an electrical circuit between them at their tips. It is noted that the electrodes in each well bottom are insulated from the surface zone and other strata above the lowest sedimentary stratum, and that the well casings are isolated from the conductive surface layer. Thus, the only available electrical path is that between the respective electrodes 22 and 26. This path passes through the resistivity of the sedimentary, or other porous and permeable, rock between the wells. This resistance is, based on available geological data, assumed to be in the order of between 1/2 ohm and 1000 ohms per meter.
The electrical cables, one from each electrode below the injection and production well, must be kept totally insulated from the surface ground, the steel tubings and the well casings. They are then connected to a variable source of electrical energy 28 (which is hereinafter described in fuller detail). The voltage, current flow and, pulse frequency are adjusted in accordance with the resistance between the two electrodes, which may be as low as 30 ohms or as high as 400,000 ohms, depending on several variables such as the physical and chemical parameters of the oil-bearing stratum, and the distance between electrodes. Typically, said distances will vary between 25 and 3,000 feet.
Initially, bursts or impulses of extremely high voltage may be required to establish a minimal current flow between the electrodes; however, a gradual charring or coking of the semi-solid hydro-carbons between the electrodes will increase conductivity and, therefore, current flow to the point where a heavier current at a lower voltage may be pulsed or sustained while the thermal, electrical and physical shock effects of the electrical energy will (a) reduce asphalt or paraffinic clogging, (b) reduce the viscosity of the oil otherwise trapped in the stratum, (c) fracture certain rock formations within the producing horizon, and between this horizon and adjacent petroleum reservoirs, (d) enlarge the area of accessible oil-bearing rock between wells, and (e) increase the well radius. Any salt water or moisture in the vicinity of the current flow will be converted to steam and, therefore, will generate steam fracture and pressure drive phenomena.
The underground temperature between electrodes will exceed 500° F., and may approach 1,200° F. It is noted that only 150° to 200° will melt asphalt or paraffin, 550° is required for charring or coking, while higher temperatures may cause "rock burst" as the "conate water" expands and explodes rock formations having little porosity, or the pressure is released on compressed rocks (by opening of adjacent passages by fracturing).
When initial fracturing and heating has been accomplished, a heavier current will be able to flow between electrodes. Accordingly, the input of both the voltage and current may be reduced while still attaining a continuous heating. This may be continued while oil recovery is in progress from the production well, as a pressure drive of the conventional type will be provided at the injection well.
It is to be noted that in the event of a lag in the quantity of recovery, the respective roles of the injection and production wells can be reversed. That is, the output lead of the power supply 28 can be attached to the recovery well, thereby using the former injection well as a recovery well.
As a second embodiment of the present inventive method, it is noted that, under those conditions where the above enumerated desired thermal, electrical and physical shock effects of the electrical energy are not sufficiently forthcoming, the current flow between electrodes 22 and 26 can simply be reversed. Such a current reversal may prove to be more effective with respect to the particular physical and chemical parameters existing within the producing horizon. That is, the phenomenom of electrolysis, galvanic action, or unidirectional flow may occur more readily in the presence of a reverse current flow, depending upon the particulars of the parameters involved.
Turning now to the design requirements of the electrical power supply 28, it is to be understood that, in essence, the present system seeks to simulate the thermal, electrical, and physical shock effect of a lightning bolt delivered at the location of electrode 22. Accordingly, it is necessary to provide an extensive network of capacitative elements having an adequate electrical energy storage capability and, further, being suitably controlled as to discharge parameters including amplitude, frequency, pulse width and energy configuratiion.
An overall system block diagram of the present circuit is shown in FIG. 3. The heart of the system consists of a collection of high-voltage, high-energy storage capacitors, labeled C-1, C-2, and C-3 in the figure. Although only three units are shown, it is expected that 12 or more such capacitors will be utilized.
Energy is received from the transformer bank and is stored in the capacitor array. Charging of the capacitors is achieved by connecting them in parallel, by means of electronic switches S-1-A, S-1-B, S-3-A, S-3-B, etc., across the transformer bank secondary. After sufficient charge is stored, the parallel-connecting switches are opened. The amount of charge stored is adjustable and is sensed by the capacitor voltage sensing system. Next the array of charged capacitors is connected in series-aiding across the probe terminals by means of series-connecting electronic switches S-0, S-2, S-4, etc. The system discharges its stored energy into the probe in a short time period, thus giving rise to high power levels. Following the discharge period, the series-connecting switches are opened, and re-charging begins. The control of the electronic switches is carried out by the series-mode and parallel-mode actuators, each receiving commands from the master controller. The length of the discharge period as well as the level of energy storage are to be variable.
FIG. 4 shows a typical parallel charging circuit. Upon receipt of a firing control signal, the capacitor is charged from the transformer secondary through S-1-A and S-1-B. The firing control signal is received at the beginning of each cycle in which charging is to take place, and the circuit will commutate naturally.
A typical series-mode discharge actuator is shown in FIG. 5. Upon receipt of a series firing control signal, switches S-0, S-2, S-4, etc. will be brought into the circuit, thus connecting the capacitor array in series mode across the probe terminals.
At the conclusion of the discharge period, the series string must be shut-down in order to reduce the pulse width of the discharge in order to obtain higher pulse frequencies. Typical shut-down circuits are shown in FIGS. 6 and 7. In FIG. 6, shut-down is accomplished by means of forced capacitor pulse communtation through a coupling transformer. In FIG. 7, shut-down is accomplished by presenting a high transformer impedance in the series string, thus effectively reducing the string current to the point of shut-down.
An auxiliary heating-mode circuit is shown in FIG. 8. A 23-KV, half-wave rectified voltage is presented to the probe terminals for long-term heating purposes. Connection of the probes to the heating circuit is accomplished by means of a DPDT high-voltage relay circuit.
The master controller is shown in FIG. 9. Action is initiated by applying the ON signal and a START pulse, which resets the flip-flop. With the flip-flop reset, AND gate "A" is enabled, and AND gate "B" is disabled. Line sync pulses are then used to trigger ONE-SHOT "A." The output of this one-shot is amplified to form the parallel firing signal. This action repeats for as many cycles as may be required to bring the capacitor voltages to the selected level. When the capacitor voltages reach the selected level, the output signal of the COMPARATOR will set the FLIP-FLOP, thus disabling AND gate "A," and enabling AND gate "B." The next line sync pulse will actuate ONE SHOT "B." Its output pulse is delayed and then amplified to become the series-firing signal. After a time period equal to the desired discharge interval has elapsed, the arriving pulse is amplified to become the series shut-down signal. A final delay period elapses and the flip-flop becomes reset again, thus beginning another charge interval.
The illustrated circuitry is capable of a discharge voltage on the order of 253,000 volts DC, a current of about 7,800 amps, and a total energy transfer of about 213 kilowatt-seconds. The minimum charge time is 1.3 seconds, while the mimimum time of discharge is about 1 millisecond.
The rapid discharge of such a high quantity of stored energy will, especially under conditions of low geological resistance, produce an enormous impulse, and electrical and physical shock effect upon the stratum of interest. Further, because of the fact that the above transfer of electrical energy represents the thermal equivalent of about 200 BTU's of heat, a considerable thermal effect will, after several minutes of operation, become noticeable. That is assuming a discharge frequency of thirty times per minute, about 6,000 BTU's will be injected into the geological structure for each minute of operation.
Inasmuch as the geological environment of interest is believed to represent an excellent thermal insulator, and thus as heat localizer, there is every reason to believe that the desired electro-fracturing effect will, after several minutes of operation, become apparent. The present invention represents, it is believed, an advance over the state of the art in that it provides for an advantageous regulation of voltages in excess of 150 kilovolts and, further, provides a control system by which vast quantities of electrical energy can be repetitiously applied in such a manner as to approximate the heating, electrical and physical shock effects of successive bolts of lightning. Also, the present system permits the ready reversal of current flow in those situations where the geological parameters are more receptive to such reverse current.
It is to be appreciated that the physical conditions involved in the present invention may be optimized by the placing of either or both of the probes 22 and 26 near a subterranean deposit of water so as to maximize the possibility of water expansion and thereby of attaining so-called rock burst phenomenon.
Also, said probes may be placed within a stratum of crystalline rock, thereby maximizing the potential for physical fracture of said strata.
Also, the electrodes may be placed in a stratum which is rich in metallic and mineral deposits so as to give rise to inductive effects which may act to enhance the possibility of fracturing through transductive phenomena.
As a further technique, the probes may be directed in a co-linear disposition with respect to each other in order to maximize the uni-directionality of current flow between the electrodes, said step being particularly applicable in geological environments of high metallic and mineral content.
A further advantageous approach comprises the step of frequency-modulating the DC current flow in order to thereby optimize the ionization of mineral molecules within the oil strata, thusly causing an electrolysis to occur and thereby creating an electrolytic condition exhibiting an enhanced current flow, especially within regions of salt water and liquid minerals which occur within oil-bearing strata.
Also, it is to be appreciated that the present method may include the step of applying said electrodes within a sedimentary stratum, thereby, by virtue of the nature of said stratum, giving rise to an electro-osmotic effect in which oil is advanced within said stratum to the cathode electrode or recovery well, while salt water is advanced in the direction of the anode or injection well.
In addition, discharge time of each pulse may be maximized in order to convey a maximum or thermal energy to water and oil deposits, thereby creating a steam or gas expansion which will provide necessary pressure in order to enhance the ease and efficiency of oil recovery. This step will enable each pulse to convey a maximum of thermal energy to deposits of oil, asphalt, and parrafine, thereby reducing the viscosity of said materials, thus enhancing their flow rates and ultimately increasing their ease or recoverability. A further benefit in maximizing the discharge time is to convey a maximum of thermal energy to the oil stratum in order to decrease the electrical resistance thereof, thus increasing the conductivity with a concommitant enchancement of total energy flow, and thus recovery efficiency, within said stratum.
An alternative pulsing method comprises the step of applying spike pulses of the highest attainable amplitude in order to create shock waves within strata of cap rock, thereby enhancing the efficiency of the fracture within said strata in order to therein open paths to new oil reserves.
A still further pulsing method includes the step of continually applying electrical energy at a fixed frequency, established amplitude, and sufficient power in order to give rise to a condition, with the stratum of interest, of a physical resonance, with a concomittant enhancement of sedimentary fracturing.
It is to be appreciated that the input parameters of frequency, amplitude and power may be selectively adjusted in order to attain a condition of physical resonance within the sedimentary stratum.
Further, the present method may include the steps of applying an AC current (including half-wave AC) between said electrodes; and selectively adjusting the input parameters of frequency, amplitude and power in order to attain a condition of physical resonance within the sedimentary stratum.
It is to be noted that the annular cavities of the wells 10 and 12 may, circumferential to the well casing 18, be filled with insulating cement, concrete, epoxy, or any other similar such insulating medium.
With respect to the circuitry, it is noted that the selective actuation of the high energy electrical impulses may be accomplished through the use of a relay or solenoid which, more particularly, may comprise thyratron, ignatron, or SCR which, preferably, would be of a gate turn-off (GTO or GTS) device.
It is thus seen that the object of obtaining an improved method for the supplemental recovery of oil has been efficiently obtained by the above described embodiments of the present invention.
While there have been herein shown and described the preferred embodiments of the present invention, it will be understood that the invention may be embodied otherwise than as herein specifically illustrated or described, and that within said embodiments certain changes in the detail and construction and the form and arrangement of the parts may be made without departing from the underlying ideas or principles of this invention within the scope of the appended claims. | The present invention relates to an improved method of recovery of petroleum from presently existing wells which are either non-producing or low production types. The method utilizes surges and oscillations of electrical energy in excess of 150 kilovolts involving the use of heavy current flow over a carbonaceous path in order to establish heat, electrical and physical shock, and steam fracturing (or shattering) within certain sedimentary rock formations, thereby giving rise to an increase in the effective well and reservoir radius both within an existing well and between wells. The method involves the use of a minimum of two existing wells, one being an injection well and the other being a production or recovery well. In each well, insulated high voltage cable is secured within the well casing in order to feed required electrical energy into a probe rod which, at the bottom of each well is driven into the oil stratum in a configuration in which each probe is directed toward the other. The distance of the respective probes from each other will, depending upon factors of voltage, current flow and geological conditions, be disposed as close as 25 feet apart or, in any given instance, as far as 3,000 feet apart. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a buckle whose female receptacle and male latch can be coupled to each other, and more particularly, to a buckle that includes a male latch having an improved shape.
2. Description of the Related Art
Generally, a buckle has been widely used in a waist belt, a knapsack for climbing, or a shoulder strap of a school bag and includes a female receptacle and a male latch.
The buckle includes a female receptacle and a male latch that are detachably connected to each other. A pair of hooks are formed at the male latch and a receiving part having elasticity is formed at the female receptacle to receive the hook of the male latch. Each of ends of the female receptacle and male latch is provided with a connector to be coupled to an end of the belt or shoulder strap (hereinafter, referred to as “belt”).
FIGS. 1 to 3 show various constructions of conventional buckles. The conventional buckles are comprised of female receptacles 12 a , 12 b and 12 c and male latches 11 a , 11 b and 11 c respectively.
A guide projection is formed at the middle of each of the male latch 11 a , 11 b and 11 c and a pair of hooks are formed at both sides thereof.
Each of the female receptacles 12 a , 12 b and 12 c is provided with an insertion part (not shown) into which the guide projection and hooks are inserted. A receiving part is formed at both sides of the female receptacle so as to be connected to the hooks of the male latch.
On the other hand, the female receptacle and male latch can be connected with the belt by the connector formed at ends thereof.
Operation of the above conventional buckle will be explained below.
The male latches 11 a , 11 b and 11 c and female receptacles 12 a , 12 b and 12 c are made of plastic for elasticity. Accordingly, arms 14 a , 14 b and 14 c and projected parts 13 a , 13 b and 13 c of the hooks of the male latches are inserted into the receiving parts of the female receptacles while they are deformed toward guide projections at the middle thereof. In this time, when the hook is located in the receiving part of the female receptacle, the hook is restored to an original state and thus the projected part 13 a , 13 b and 13 c is engaged with a hooked projection of the receiving part. Thus, the male latch and female receptacle are coupled to each other.
To the contrary, when the hook of the male latch 11 a , 11 b or 11 c located in the receiving part of the female receptacle 12 a , 12 b or 12 c is pushed inward by a user, the projected part 13 a , 13 b or 13 c of the hook is released from the hooked projection of the receiving part, thereby allowing the female receptacle and male latch to be separated from each other.
However, in the conventional buckle, a projected surface of the projected part 13 a , 13 b or 13 c of the hook to be contacted to the hooked projection of the receiving part is formed at one or two side surfaces. Accordingly, coupling force between the male latch and female receptacle is weak and thus the male latch may be separated from the female receptacle even by low external pressure.
For example, as shown in FIG. 1 , it is disclosed in the registered Korean Patent publication No. 0452565 that a projected part 13 a of a hook of a male latch 11 a is extended likely to surround an outer surface of an arm 14 a with different heights. The hook of the male latch 11 a includes a ‘V’ shaped protruded surface that surrounds only an upper surface of the arm 14 a , that is, the whole first surface, and both side surfaces, that is, very small portions of second and third surfaces of the arm. A projected part 13 b of a hook of a conventional male latch 11 b shown in FIG. 2 is extended in the same height from the both side surfaces, that is, second and third surfaces of the arm. In addition, a projected part 13 c of a hook of a conventional male latch 11 c shown in FIG. 3 is formed of a rectangular protruded surface extended in the same height from an upper surface, that is, a first surface of the arm 14 c.
In other words, the projected parts 13 a , 13 b and 13 c of the conventional buckles are projected from one or two side surfaces and thus contact surface with the hooked projection is small. Accordingly, there is a problem that coupling force between the projected part and hooked projection is reduced.
In addition, in the above conventional buckles, the projected part of the male latch is formed of only one or two protruded surfaces and thus force is less distributed. Accordingly, when excessively strong force is applied from the belt, the projected parts 13 a , 13 b and 13 c , or the hooked projection of the female receptacle may be damaged to cause the buckle to be released.
BRIEF SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a buckle that includes a projected part formed on a hook of a male latch, where the projected part includes three projected surfaces projected from three side surfaces of an arm.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention.
According to an aspect of the present invention, there is provided a buckle, which comprises: a male latch including a pair of hooks each of which has three projected surfaces; and a female receptacle coupled to the male latch by holding the projected surfaces formed on the each hook of the male latch, where the male latch can be inserted into the female receptacle.
The male latch may include a first end connected to a first belt and a pair of hooks each of which is extended from the first end and respectively have three projected surfaces at an end thereof.
The female receptacle may include: a second end connected to a second belt; an insertion part formed at the opposite side to the second end where the pair of hooks are inserted into the insertion part; and a receiving part that makes the three projected surfaces formed at the end of the each hook to be projected out of the insertion part and fixes the projected surfaces.
Each hook may include an arm extended from the first end, and a projected part having the three projected surfaces that are projected from three side surfaces of the arm at the end of the arm.
The projected part may include a first projection having a first projected surface projected from a first surface forming an upper surface of the arm, a second projection having a second projected surface projected from a second surface forming a left surface of the arm, and a third projection having a third projected surface projected from a third surface forming a right surface of the arm.
The three projected surfaces of the projected part may be inclined at a predetermined angle about a direction perpendicular to a length direction of the arm.
An upper part of each projected surface of the projected part may be rounded.
The projected part may further include a support part projected in the direction opposite to the first projection.
The male latch may further include a guide projection that is extended from the first end and interposed between the pair of hooks.
The first projection may be formed to be stepped from the second and third projections.
The receiving part may be formed in a shape of being curved toward the middle of the female receptacle from edges of both side surfaces thereof.
A hooked projection supporting the three projected surfaces may be formed on a surface facing an open surface of the insertion part among the four surfaces forming the receiving part.
A support member supporting the hooked projection may be formed on a surface inward from the hooked projection on an inner surface of the female receptacle.
A guide for the guide projection may be formed inside the female receptacle.
BRIEF DESCRIPTION OF DRAWINGS
The above objects, other features and advantages of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which:
FIGS. 1 to 3 are exemplary views illustrating various constructions of conventional buckles;
FIG. 4 is a perspective view illustrating a state that a male latch and a female receptacle of a buckle according to the present invention are separated from each other;
FIG. 5 is a detailed perspective view illustrating the female receptacle shown in FIG. 4 ;
FIG. 6 is a detailed exemplary view illustrating a hook of the male latch shown in FIG. 4 ;
FIG. 7 is another detailed exemplary view illustrating the hook of the male latch shown in FIG. 4 ; and
FIG. 8 is a perspective view illustrating a state that the male latch and female receptacle of the buckle are coupled to each other.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawing. The aspects and features of the present invention and methods for achieving the aspects and features will be apparent by referring to the embodiments to be described in detail with reference to the accompanying drawings. However, the present invention is not limited to the embodiments disclosed hereinafter, but can be implemented in diverse forms. The matters defined in the description, such as the detailed construction and elements, are nothing but specific details provided to assist those of ordinary skill in the art in a comprehensive understanding of the invention, and the present invention is only defined within the scope of the appended claims. In the entire description of the present invention, the same drawing reference numerals are used for the same elements across various figures.
FIG. 4 is a perspective view illustrating a state that a male latch and a female receptacle of a buckle according to the present invention are separated from each other and FIG. 5 is a detailed perspective view illustrating the female receptacle shown in FIG. 4 .
As shown in FIG. 4 , the buckle includes a male latch 110 and a female receptacle 120 . It is desirable that the male latch 110 and female receptacle 120 are made of plastic material to secure elasticity.
The male latch 110 includes a first end 111 coupled to a belt, a guide projection 112 projected from the middle of the first end and a pair of hooks 115 projected from both side surfaces of the first end about the guide projection. Particularly, the hooks are formed to be coupled to the female receptacle.
The first end 111 of the male latch is coupled to the belt. As shown in FIG. 4 , a connector is formed at one side of the first end and the belt can be inserted and fixed in the connector. The guide projection and pair of hooks are projected at the other side of the first end.
The guide projection 112 is formed at the middle between the pair of hooks. A reference position for insertion into the female receptacle is determined by the pair of hooks. However, the guide projection may not be formed.
The hooks 115 are projected from both side surfaces of the first end about the guide projection and actually coupled to the female receptacle by being inserted into the female receptacle. As shown in FIG. 4 , the hook includes an arm 113 extended from the first end and a projected part 114 having three projected surfaces projected from three side surfaces at the end of the arm.
In other words, the projected part 114 includes a first projection 114 a having a first projected surface projected from an upper surface of the arm, that is, a first surface, a second projection 114 b having a second projected surface projected from a left surface of the arm, that is, a second surface, and a third projection 114 c having a third projected surface projected from a right surface of the arm, that is, a third surface.
The hooks are coupled to the female receptacle 120 by being inserted therein. The female receptacle includes a second end 121 coupled to the belt, an insertion part 125 formed at the opposite side to the second end in order to receive the pair of hooks and guide projection of the male latch, and a receiving part 122 that makes the projected parts of the hooks inserted through the insertion part 125 to be projected out of the insertion part and fixes the each projected part.
The second end 121 of the female receptacle is coupled to the belt. As shown in FIG. 4 , a connector is formed at one side of the second end and the belt can be inserted and fixed in the connector.
The insertion part 125 is formed to have an open surface at the opposite side to the second end. The pair of hooks (and guide projection) are inserted through the open surface of the insertion part. On the other hand, when the guide projection is formed at the male latch, a guide 126 may be further provided to guide the guide projection 112 . In other words, the pair of hooks formed at both sides of the guide projection can be exactly inserted into the receiving part by aligning the guide projection by the guide.
The receiving part 122 is provided to make the projected parts 114 formed at the hooks inserted through the insertion part to be projected out of the insertion part and simultaneously prevent the projected parts from being separated from the female receptacle. The receiving part is formed in a shape of being curved toward the middle of the female receptacle from edges of both side surfaces thereof. In addition, the outside and inside of the female receptacle are communicated with each other through the curved portion. Accordingly, the projected parts inserted into the female receptacle through the insertion part can be projected out of the female receptacle through the receiving part.
On the other hand, as shown in FIG. 4 , a hooked projection 123 having a shape similar to the projected part is formed on a surface facing an open surface of the insertion part among the surfaces forming the receiving part 122 in order to make the projected parts to be projected out of the receiving part and prevent the projected parts from being separated from the receiving part. The hooked projection may be formed in the same shape as the three projected surfaces so as to allow the projected parts to pass through or be hooked.
In addition, as shown in FIG. 5 , a support member 124 supporting the hooked projection is formed on the surface inward from the hooked projection, that is, on the inner surface of the female receptacle where the hooked projection is formed. In other words, the hooked projection should have higher durability than other portions because force is applied to the hooked projection when it is coupled to the projected parts. Accordingly, the support member 124 may be additionally provided the surface inward from the hooked projection.
FIG. 6 is a detailed exemplary view illustrating a right surface of the hook of the male latch shown in FIG. 4 .
The hook 115 of the male latch are projected from both side surfaces of the first end and actually coupled to the female receptacle by being inserted into the female receptacle.
The hook 115 includes the arm 113 extended from the first end thereof and the projected part 114 having projected surfaces projected the end of the arm. Particularly, the projected part 114 has three projected surfaces. In other words, a first projection 114 a forming a first projected surface of the projected part is projected from an upper surface of the arm, and a third projection 114 c forming a third projected surface of the projected part is projected from the right surface of the arm.
A second projection 114 b forming a second projected surface of the projected part is projected from the left surface of the arm. The second projection 114 b is formed at the side opposite to the third projection 114 c and thus not shown in FIG. 6 .
As shown in FIG. 6 , the projected surfaces of the projected part are inclined at a predetermined angle about a direction perpendicular to the length direction of the arm. In other words, the projected surfaces of the projected part may be perpendicular to the surface of the arm. However, the projected surfaces of the projected part may have a predetermined angle (less than 90°) in order to increase surface area or distribute force more efficiently.
On the other hand, a supporting part 114 d projected downward a lower part of the projected part in FIG. 6 supports the projected part. In other words, the supporting part 114 d is connected to all of the first to third projected parts, thereby supporting them.
FIG. 7 is another detailed exemplary view illustrating the hook of the male latch shown in FIG. 4 and particularly shows a sectional surface of the hook when it is observed in the direction of “A” of FIG. 6 .
In other words, FIG. 7 shows the shape of the projected part of the hook in more detail and particularly shows the sectional surface of the hook when it is observed in the direction of “A” of FIG. 6 after the arm is cut.
Accordingly, a hatched portion of FIG. 7 is the sectional surface of the cut arm 113 . A portion projected over the arm is the projected surface of the first projection 114 a . A portion projected to the left of the arm is the projected surface of the second projection 114 b . A portion projected to the right of the arm is the projected surface of the third projection 114 c , and a portion projected below the arm is a supporting part 114 d . In addition, round surfaces formed on the second and third projections 114 b and 114 c are shown because upper surfaces of the second and third projected parts are projected upward in round shape.
On the other hand, upper surfaces of the first to third projected parts may form in one continuous round surface but, in the embodiment, are stepped in the shape of stairs. In other words, boundary surfaces between the first and second projections 114 a and 114 b and between first and third projections 114 a and 114 c are stepped as shown in FIG. 7 . The above construction of the present invention may be helpful to design and to save materials.
FIG. 8 is a perspective view illustrating a state that the male latch and female receptacle of the buckle shown in FIG. 4 are coupled to each other. Operation method of the buckle will be explained below with reference to FIGS. 4 to 8 . For convenience of explanation, it is assumed that the guide projection is formed at the buckle. However, the guide projection may not be formed at the buckle.
When a user wants to combine the male latch 110 and female receptacle 120 with each other, first the user inserts one pair of hooks of the male latch and the guide projection 112 into the insertion part 125 of the female receptacle 120 . In this time, the guide projection may be guided by the guide 126 formed on the inner surface of the female receptacle.
On the other hand, when the projected part 114 is inserted into the insertion part and then fitted in the receiving part, the projected part 114 is deformed in the direction of the guide projection at the middle thereof. In other words, the hooked projection 123 of the receiving part 122 is closer to the center of the female receptacle rather than the position of the projected part inserted through the insertion part. Accordingly, the projected part passed through the hooked projection is bent in the direction of the guide projection, that is, in the direction of the center of the female receptacle. Thus, the arm 113 supporting the projected part is also bent in the direction of the center of the female receptacle.
However, when the projected part 114 passes through the hooked projection completely and then reaches the opening of the receiving part 122 , the arm 113 formed of elastic body is deformed to the original position, that is, to the direction of the outer edge of the female receptacle by restoring force. Accordingly, the projected part 114 is also restored to the original position.
When the projected part is restored to the original position, the projected part is hooked on the hooked projection of the receiving part. Accordingly, the male latch and female receptacle are combined with each other. In other words, the three projections 114 a , 114 b and 114 c of the projected part are hooked on the hooked projection and thus cannot be returned toward the insertion part, thereby keeping the male latch and female receptacle combined with each other.
Next, when the user wants to separate the male latch 110 and female receptacle 120 from each other, the user pushes the projected part 140 of the male latch 110 located in the receiving part 122 of the female receptacle 120 toward the inside of the female receptacle.
Then, the arm is also bent toward the inside of the female receptacle because the arm is formed of elastic body as described above. Accordingly, the projected part 114 passes through the hooked projection of the receiving part and thus the male latch can be separated from the female receptacle.
The arm 113 of the male latch separated from the female receptacle is restored to the original shape by restoring force.
It should be understood by those of ordinary skill in the art that various replacements, modifications and changes in the form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims. Therefore, it is to be appreciated that the above described embodiments are for purposes of illustration only and are not to be construed as limitations of the invention.
The buckle according to the present invention produces the following effects.
First, the projected part formed at the hook of the male latch has three projected surfaces at three side surfaces of the arm and thus the coupling area with the female receptacle is increased. Accordingly, the coupling force of the buckle is increased.
Second, the force is distributed to the three projected surfaces, thereby preventing the projected part of the male latch or the hooked projection of the female receptacle from being damaged.
It should be understood by those of ordinary skill in the art that various replacements, modifications and changes in the form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims. Therefore, it is to be appreciated that the above described embodiments are for purposes of illustration only and are not to be construed as limitations of the invention. | The present invention relates to a buckle that includes a male latch having an improved shape. An object of the present invention is to provide the buckle that includes a projected part formed on a hook of the male latch, where the projected part has three projected surfaces projected from three side surfaces of the arm. The buckle comprises: the male latch including a pair of hooks each of which has three projected surfaces; and a female receptacle coupled to the male latch by holding the projected surfaces formed on the each hook of the male latch, where the male latch is inserted into the female receptacle. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates generally to semiconductor chip wire bonding devices, and similar bonding apparatus, and particularly to a method and apparatus for locating a ball bond formed on a pad of a semiconductor chip, in order to perform automated optical inspection of wire bonding in such a device.
Semiconductor devices, such as integrated circuit chips, are electrically connected to leads on a lead frame by a process known as wire bonding. The wire bonding operation involves bonding a wire to electrically connect pads residing on a die (semiconductor chip) to a lead in a lead frame. Once the chip and lead frame have been wire bonded, they can be packaged in ceramic or plastic to form an integrated circuit device. A post-process inspection step, commonly called the third optical inspection, typically involves locating the position of all bonds on the device, the wire connections and the wire heights using optical means.
Heretofore the third optical inspection has been accomplished only after the device is completely bonded and sent to a separate machine or operator. In the majority of cases, the inspection is done by a human operator using a microscope. This manual method can be time-consuming and costly.
Separate machines are available to perform this step, but this requires another piece of capital equipment in the production line. Additionally, a post-process inspection machine has a more difficult time locating the bond to perform a successful inspection because all the information about the chip that was available during the bonding operation, such as exact pad and frame positions and information about other detail have been lost.
This is further complicated by the fact that most semiconductor chips have a considerable amount of visual detail (such as the images of the circuits themselves) which must be circumvented in analyzing the post-bond image to find the bonds. In post-process inspections, some of this detail can be mistaken for parts of the bonds.
Automatically locating the center of a ball bond in an image is required to accurately detect the presence or absence of the ball bond on a pad on a semiconductor die; to find the bond's precise location on a pad, and to serve as a principal step in automating the inspection of the quality of a connection to a pad.
Machine vision systems or image processing systems (systems that capture images, digitize them and use a computer to perform image analysis) have been used on wirebonding machines to align devices and guide the machine for correct bonding placement, but have heretofore not been used during the process to locate the bonds formed and inspect them.
Where post process inspections are automated, the visual detail that is unrelated to the bond may be misinterpreted as part of the bond in a post-process inspection, giving rise to erroneous acceptance or rejection rates. Visual imperfections on the pads and leads caused by probe marks, discoloration, or imperfect illumination further complicate these difficulties. These blemishes may be misconstrued as defects in the bonding process, without the information that was available during the bonding operation.
An additional problem encountered in attempting to perform the inspection in-process can be created by the differences caused by bonding itself. Depending on the type of bonding process and equipment used, heating, cooling, movement and other mechanical factors can create alignment problems for images taken before and after the bonding process, thus making it harder to locate the bond. Thus, ball bonds are typically located by hand in a manual inspection procedure, since there are no accepted techniques in the field for automatically locating ball bonds in images.
Using normalized correlation templates is an accepted machine vision technique to find objects in imagery, but with this technique the template is extremely specific to the object at hand and not flexible enough to handle variations in size or shape. Ball bonds, although generally circular or elliptical, are likely to vary significantly in size and shape.
One approach which has been tried involves foregoing any attempt to automatically locate the ball bond after bonding, because of the difficulties mentioned above. In this approach a system would assume that the bonds have been (correctly) placed by the wire bonder machine, as guided by the machine vision system, and the system would use those nominal locations on the semiconductor die as the precise ball bond location. The problem with this approach is that a typical wire bonder machine's inaccuracies in positioning will very frequently cause the later inspection step to fail.
SUMMARY
The present invention generates a synthetic, flattened cone-shaped model to use with a normalized correlation search in order to locate ball bonds on an image of a semiconductor die pad as part of an automatic in process inspection or an automatic post process inspection. According to a preferred embodiment of the present invention, the synthetic flattened cone shaped model is created by selecting a central diameter and a monotonically increasing slope parameter to create a template having an inner diameter no smaller than the smallest expected bond size and an outer diameter no larger than the largest expected ball size. These diameters are chosen by considering the minimum enclosed circle and maximum enclosing circle of the ball bonds that would be observed in a visual inspection system. The inner diameter should be no smaller then the minimum enclosed circle that will be observed and the outer diameter should be no larger then the maximum enclosing circle.
In a preferred embodiment of the present invention, a portion of the resulting model is suppressed such that a wedge or pie-shaped area is created in the general area where the wire should be positioned. Confusion caused by the non-circular shape of the wire is thus reduced for the search process.
The cone shaped search model of the present invention is synthesized by setting the grey value to ##EQU1## and optionally not defining the template at angles ±b degrees near the incident wire angle, w.
The present invention uses the cone shaped search model as the template for a normalized correlation search that is performed by the vision processor or image processing system after wire bonding has occurred. In a preferred embodiment, the results of the search will indicate the presence, and hence the location, of the ball bond as a peak in the computed correlation. The absence of a peak indicates that the ball bond is not present. From the location coordinates returned by the search, a nominal center of the ball bond is calculated and passed to the system for use in the next inspection steps. It is an object of the present invention that a single flexible normalized correlation template can be created and used to detect all ball bonds on a semiconductor die pad, thus avoiding the requirement of building a special ball bond template for every possible size and shape ball bond. It is a feature of the present invention that the single flattened cone-shaped template is appropriate for locating the position of ball bonds in images even as the bonds vary in radius and circularity.
It is yet another feature that since normalized correlation is used, the system is insensitive to linear changes in illumination in the image.
Another aspect of the present invention is that the single flattened cone-shaped template is appropriate for locating the position of ball bonds in images even as the bonds vary in radius and circularity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a system incorporating the present invention.
FIG. 2 is a diagrammatic view, taken from above, of a semiconductor chip or die in a lead frame.
FIG. 3 shows a side view of a bond formed on a pad connected to a lead on a lead frame.
FIG. 3a shows a top view of a bond formed on pad of a semiconductor chip, together with a wire extending from a ball bond.
FIG. 4 is a plot of a cone shape.
FIG. 5 is a top view of a flattened cone shaped model according to the method and apparatus of the present invention.
FIG. 6 is a top view of a preferred embodiment of the flattened cone shaped model of the present invention showing a wedge-shaped portion of the model which is blank.
FIG. 7 is a side view of a diagram of a cone, indicating the areas of importance for generating a flattened cone-shaped model according to the method and apparatus of the present invention.
FIG. 8 is a flow diagram of the principal operations of the present invention.
FIG. 9 contains pseudo code illustrating the invention.
FIG. 10 contains code in the C computer language used in a preferred embodiment to create a cone model.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a system incorporating the present invention is shown. The system includes a wire bonding machine having a movable platform such as an X-Y table 70 for holding semiconductor chips 20 situated in a lead frame 10; a video camera 80 or other optical sensing device for generating images, which camera is typically positioned over the target chip and lead frame 10 to be bonded; illumination means 100 for illuminating the chip in a lead frame; an image processor 90 capable of digitizing and analyzing the optically sensed images; bonding mechanism 22; and host controller 60 electronically connected to the bonding 22, the movable platform 70, the camera 80, and the image processor 90.
FIG. 2 depicts a semiconductor chip 20, in a lead frame 10, having pads 40, and leads 30. The wire bonding process bonds a conductive wire between each pad on the chip 20 and its respective lead 30 on lead frame 10.
FIG. 3 shows a side view of a ball bond 110, connecting a pad 40 to a lead 30, on a lead frame 10 by a wire 50. In a typical wire bonding device, a wire 50 or filament is extruded by the bonder and deposited on the die pad and extended to the lead frame, where the wire is also affixed, to form an electrical connection.
FIG. 3a shows a top view of a bond formed on a pad 40 of a semiconductor chip 20, together with a wire 50 extending from ball bond 110. In a preferred embodiment of the present invention, an approximate location of a bond 110, on a pad 40, is found using Applicant's Assignee's co-pending applications: Automated Optical Inspection Apparatus filed 06 Oct. 1993, Ser. No. 08/132,532 Attorney Docket No. C93-007 (now abandoned) and the co-pending file wrapper continuation thereof, Automated Optical Inspection Apparatus application Ser. No. 08/389,437 (now allowed), Attorney Docket No. C93-007FWC, filed Feb. 15, 1995; and Automated Optical Inspection Apparatus Using Nearest Neighbor Interpolation, filed 02 May, 1994, Ser. No. 08/236,215 (now pending).
Proceeding to FIG. 4, a plot or graph of a cone shape is illustrated. The axes of the graph show grey level values on the y axis, indicated here as k, and the locations of r-inner, r-outer, and a center point on the x axis, indicted here as r. The present invention uses these and other values to create a flattened synthetic cone shaped model 120, as shown in FIG. 5.
Here, in FIG. 5, a model is depicted containing three different grey levels. An innermost circle, having an inner diameter, is depicted here as the lightest valued. An outermost circle, having an outer diameter, is shown having a darkest value. The central circle between these two has an intermediate grey level. As will be apparent to those skilled in the art, these gray levels can be reversed if the polarity of the image to be analyzed or the system used to conduct the search requires it. It is also apparent to those skilled in the art that additional grey levels could be created, if desired. In a preferred embodiment a model contains up to 254 grey levels.
Turning to FIG. 7, the significant parameters used to create the flattened synthetic cone shaped model are illustrated in a schematic side view of a cone. A cone having an inner diameter, no smaller than the smallest expected bond size is selected by considering the maximum size circle that will be enclosed by the smallest expected bond. Similarly, a maximum outer diameter for the cone is selected by considering the minimum size circle that will enclose the largest expected bond. A number of ways to determine this will be apparent to those skilled in the art. For example, representative images of actual bonds can be created (either online or offline from the actual inspection.) These, in turn may be compared to find the smallest and largest sizes, and synthetic circles created from them. Alternatively, these can be created completely synthetically, based on known characteristics of the bonding apparatus.
Still in FIG. 7, a central diameter, between inner diameter and outer diameter is selected. The radii of these circles are used to create a monotonically increasing slope parameter k, that is a slope parameter, is created which never decreases or creates a dip or valley in the outer slope of the cone.
Referring now to FIG. 9, the overview of the creation of a flattened synthetic cone shaped model is illustrated by pseudo code. In this example, the grey level of the innermost circle is referred to as the plateau value. In the pseudocode, a value of 254, represents a very light value. NM is used for a pixel value that is not to be considered part of the model. In a preferred embodiment this is used and is called a "don't care" pixel, which is ignored by the normalized correlation search. Referring now to FIG. 9, the pseudo code, it can be seen that the flattened synthetic cone shaped model creation iterates through each pixel in the model image, starting from the top left and going from left to right across one row, then moving down to the next. In FIG. 9, the radius of a first pixel location is computed, by taking the square root of [(x-centerx) 2 +(y-centery) 2 ]. If the radius for a pixel location is less than r inner, (in these examples, the pixels near the center of the image), then the pixel at that location is set to the plateau value. In the FIG. 9 example, the plateau value is set to 254, and the innermost pixels will have that value. Continuing with the pseudocode in FIG. 9, the grey level of the outermost circle locations are set to the grey level appropriate for that place on the slope, if it less than r outer. For the intermediate levels, grey level is set to a value calculated as slope times (r outer minus the radius (r)) at that point on the slope.
If the radius for a given pixel location is larger than r outer the value for that location is set to NM, or whatever that vision processor system uses to indicate that pixel is not in the model.
In a preferred embodiment, software code written in the C language is used to create the model, as illustrated in FIG. 10. Any of a number of variations of software embodiments of this code could be created in C or other computer languages, such as assembler.
It will be apparent to those skilled in the art that a model resembling the flattened synthetic cone shaped model generated according to the method and apparatus of the present invention could be created by arbitrarily creating a pixel model having three or more varying grey levels in concentric circles set as constants. However, a different model would have to be created for each different wirebonder or each different chip and bond size. Given the typical variations in bond sizes, arbitrary models thus constructed would be more difficult to use and manage.
In a preferred embodiment, creating the flattened synthetic cone shaped model according to the method and apparatus of the present invention permits the model to be modified to accommodate the confusion caused by the protrusion of the wire from the bond. In FIG. 6, such a modification is shown.
In FIG. 6 a wedge shape or pie slice around the angle of the wire is suppressed when the model is created. Specifically, if the wire angle is w, the wedge shaped area b, is created around the wire angle. In a preferred embodiment this is accomplished by inserting NM or don't care pixels for the pixels in that area.
Turning now to FIG. 8, it can be seen that a first step A, of the invention is the creation of the flattened synthetic cone shaped model as described above. In a preferred embodiment this is done offline, but it can also be created online during a bonding and inspection process.
In Step B of FIG. 8, the flattened synthetic cone shaped model created according to the method and apparatus of the present invention is used as the model for a normalized correlation search in the area of the image at the nominal or expected location of the bond. This step is performed at runtime or online, either in an in-process inspection embodiment or in can also be done at runtime in an offline post process inspection embodiment. As is known to those skilled in the art, normalized correlation is a measure of the geometric similarity between an image and a model, independent of any linear differences in image or model brightness. The normalized correlation value does not change in either of the following situations: if all image or model pixels are multiplied by a constant if a constant is added to all image or model pixels. This independence of normalized correlation from linear brightness changes is one of its most important attributes.
The result returned by the search is a correlation coefficient, which indicates the extent to which the image matches the model, and an x,y location in the image indicating the center of the image found to be matching. A perfect match would equal a 1, near matches would be some value less than 1, such as 0.95. In a preferred embodiment a normalized correlation search that accepts and reports on threshold values is used. For example, a user could specify that images with a correlation coefficient less than 0.50 would not be considered matches. In that case, the search would return a not found signal if all results are lower than the threshold.
In a preferred embodiment, in which the nominal location of the bond has been found before application of the flattened synthetic cone shaped model, a low threshold value is set for the normalized correlation search with the model so that not found signals are generated infrequently or not at all. The location having the largest coefficient returned by the normalized correlation search is assumed to represent the location of the solder ball, if it is above the specified threshold.
Once the solder ball has been located more precisely according to the method and apparatus of the present invention, its actual location is signaled to a next module in the vision processor or host controller, so that inspection of the ball can continue.
Those skilled in the art will appreciate that the embodiments described above are illustrative only, and that other systems in the spirit of the teachings herein fall within the scope of the invention. It will also be apparent to those skilled in the art that the present invention can be used to locate portions of objects similar to rounded bonds on a semiconductor chip, either as part of a manufacturing step, or as a post process inspection.
A preferred embodiment of the present invention also includes a camera or other device for generating a video or image signal. The video signal generated by the camera is typically converted from analog to digital by techniques well known in the art and sent to an image memory, such as a frame grabber, or similar device for storing images. A vision processor system, which includes a computer central processing chip, and input/output capabilities, is coupled to the image memory and is used to perform image processing and analysis according to the present invention. Portions of image processing and analysis are accomplished by software programs controlling the vision processor system, or, as will be evident to one skilled in the art, can be controlled by equivalent circuits created in special integrated circuit chips. The results of image processing and analysis are transmitted electronically to the apparatus or system requiring the machine vision results. Alternatively, the machine vision function can be incorporated within and work as part of a larger system. | Method and apparatus for automatically locating the center of a ball bond of a wire to a lead frame and semiconductor chip or similar device; analyzing the optically sensed images; a bonding mechanism; and a host controller connected to the bonding mechanism, the movable platform. The present invention constructs a synthetic flattened cone model using a center radius, and monotonically increasing slope values to generate a model having a variation in grey levels, and inner and outer radii that will encompass expected size variations in a ball bond; sets a threshold for acceptable normalized correlation search results; acquires a digitized image of the bond, including a nominal location for the bond; conducts a normalized correlation search of the digitized image at the bond location, using the flattened synthetic cone model; and indicates the presence and location of the expected circular object as the location having the largest coefficient which exceeds a threshold. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the priority of U.S. Provisional Patent Application Ser. No. 61/830,534 filed Jun. 3, 2013, which application is incorporated in its entirety herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to extension ladder accessories and in particular to a paint can shelf attachable to a sliding extension ladder fly section.
Painters have been faced with the problem of supporting a paint can on an extension ladder for many years. Various holders have been developed and marketed, but none have succeeded to provide a good solution.
BRIEF SUMMARY OF THE INVENTION
The present invention addresses the above and other needs by providing an extension ladder paint can shelf which attaches to a sliding extension ladder fly section and slides against a fixed extension ladder section. The shelf includes two parallel arms which reach through hollow rungs of the sliding extension ladder fly section, whereby the shelf is raised and lowered with the sliding extension ladder fly section. Slides are attached to the arms on each side of the sliding extension ladder fly section and include low friction surfaces facing the fixed extension ladder section. The slides allow somewhat loose tolerances in the engagement of the arms with the ladder preventing the ladder sections from binding when the ladder is extended or lowered.
In accordance with one aspect of the invention, the extension ladder paint can shelf includes a slide residing against a face of an extension ladder base section side rail. The hollow rungs of the fly section of the extension ladder are only slightly displaced outward from the face and typical extension ladder tolerance do not facilitate an extension ladder paint can shelf spaced outward from the face of the base section side rail. To prevent binding when the ladder is extended or lowered, a low friction material is attached to the side of the slider facing the rail face. The material may be, for example, metal, plastic, TEFLON® material, TURCITE® material, and the like.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
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. 1 shows a perspective view of a prior art extension ladder.
FIG. 2 shows a perspective view of a paint can shelf according to the present invention for use with the extension ladder.
FIG. 3 shows an exploded perspective view of the paint can shelf according to the present invention with the extension ladder.
FIG. 4A shows a perspective view of the assembled paint can shelf according to the present invention attached to the extension ladder.
FIG. 4B shows a front view of the assembled paint can shelf according to the present invention attached to the extension ladder.
FIG. 5A is a side view of a bent elbow of the paint can shelf according to the present invention.
FIG. 5B is a front view of the bent elbow of the paint can shelf according to the present invention.
FIG. 6 shows a perspective view of a slide member of the paint can shelf according to the present.
FIG. 7A shows a side view of the slide member of the paint can shelf according to the present.
FIG. 7B shows a rear view of the slide member of the paint can shelf according to the present.
FIG. 8 shows a cross-sectional view of arms of the paint can shelf according to the present residing in ladder rungs.
FIG. 9 shows a compressible ring according to the present invention around a top edge of a paint can recess in the paint can shelf.
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 one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
A perspective view of a prior art extension ladder 10 is shown in FIG. 1 . The extension ladder 10 includes a stationary base section 12 and an extending fly section 16 . The base section 12 include a base section side rails 14 a , and the fly section 14 includes fly section slide rails 14 b , and hollow rungs 18 . The fly section 16 can be lowered to generally align with the base section 12 for a minimum ladder length, or can be extended with respect to the base section 12 to obtain a longer ladder 10 . The ladder 10 is leaned at an angle A 1 during use to provide stability. The angle A 1 is preferably 13 to 17 degrees from vertical.
A perspective view of a paint can shelf 20 according to the present invention, for use with the extension ladder 10 , is shown in FIG. 2 , an exploded perspective view of the paint can shelf 20 is shown in FIG. 3 , a perspective view of the assembled paint can shelf 20 attached to the extension ladder 10 is shown in FIG. 4A , and a front view of the assembled paint can shelf 20 attached to the extension ladder 10 is shown in FIG. 4B . The paint can shelf 20 includes a first slide 24 a on a left side of the paint can shelf 20 , parallel upper arm 22 a and lower arm 22 b , a second slide 24 b opposite to the first slide 24 a , a bent leg 26 , and a shelf 28 . The arms 22 a and 22 b may be permanently attached to the first slide 24 a , or attachable to the first slide 24 a , and when attached to the first slide 24 a , extends a length L from the first slide 24 a , the length L preferably about 18 and ¾ inches. The arms 22 a and 22 b extend through the hollow rungs 18 of the extending fly section 16 , passages 40 a and 40 b respectively (see FIG. 5A ) of the second slide 24 b , and through the bent leg 26 far enough to attach locks 32 to exposed ends of the arms 22 a and 22 b , retaining the bent leg 26 , while positioning the slides 24 a and 24 b facing the faces 15 (see FIG. 4 ) of the base section side rail 14 a (see FIG. 1 ), and sandwiching the extending fly section 16 of the ladder 10 between the slides 24 a and 24 b . The locks 32 may be pins, lynchpins, nuts, or any apparatus attachable to exposed ends of the arms 22 a and 22 b . A cylindrical recessed area 30 is configured to accept a paint can provided in the shelf 28 . Additional features may be provided in the shelf 28 , the features including a slot 31 accepts a scraping or putty knife or the like, and various passages 33 accept brushes and tools of various types, and the like. The arms 22 a and 22 b preferably have a diameter D 1 of preferably one inch.
A side view of the bent elbow 26 is shown in FIG. 5A and a front view of the bent elbow 26 is shown in FIG. 5B . The bent elbow 26 includes two passages 40 a and 40 n for the arms 22 a and 22 b , the passages 40 a and 40 b spaced apart by a separation S of preferably between ten and fourteen inches and more preferably about twelve inches. The bent elbow 26 has a vertical centerline CL and the passages 40 a and 40 b are connected by a second centerline CL 2 . The centerlines CL and CL 2 are separated by the angle A 2 preferably matching the angle A 1 of the extension ladder 10 to provide a generally horizontal shelf 28 . A diagonal brace 27 provides support for the shelf 28 . The angle A 2 is preferably between 13 and 17 degrees and more preferably about 15 degrees. The recessed area 30 had a depth D 1 and diameter D 2 for receiving and holding the paint can. The depth D 1 is preferably at least about three inches deep to prevent the paint can from escaping from the recess 30 when the ladder 10 is moved, and is more preferably about three inches deep, for example, between 2.5 and 3.5 inches deep. The diameter D 2 is preferably between 6.5 and seven inches and more preferably at least about 6.5 inches and more preferably about 6.75 inches.
A perspective view of the slide member 24 b is shown in FIG. 6 , a side view of the slide member 24 b is shown in FIG. 7A , and a rear view of the slide member 24 b is shown in FIG. 7B . The slide member 24 b includes two passages 41 a and 41 b for the arms 22 a and 22 b , the passages 41 a and 41 b spaced apart by a separation S. A low friction plate 42 is attached to the rear surface of the slide member 24 b , the plate 42 faces, or lays against, a face 15 (see FIG. 4 ) of the base section side rail 14 a . A ramp 50 may be present at one or both ends of the slide member 24 b and helps the slide member 24 b to slide along the face 15 .
The passages 41 a and 41 b have a diameter D 2 of preferably about one inch and allow the arms 22 a and 22 b to slide through the passages 41 a and 41 b . The centers of the passages 41 a and 41 b are offset a distance O, of preferably about one inch, from the rear surface of the plate 42 . The diameter D 2 and offset O allow the paint can shelf 20 to slide on, or avoid contact with, the face 15 (see FIG. 4 ) of the base section side rail 14 a when the ladder 10 is extended or lowered. The slide member 24 b has a width W of preferably about 2¼ inches and a height H of preferably about fifteen inches. The slide member 24 a preferably has the same dimensions D 2 , O, S, W, and H as the slide member 24 a and may include a low friction plate 42 . The low friction plate 42 may be made from TEFLON® material, TURCITE® material, a hard metal material, or the like. The slide member 24 a (see FIG. 3 ) may have all or some of the features of the slide member 24 b shown in FIGS. 6 , 7 A, and 7 B.
A cross-sectional view of the arms 22 a and 22 b residing in the ladder rungs 18 is shown in FIG. 8 . In one popular ladder 10 the arms are preferably spaced apart a separation S 2 of about eleven inches, and the arms 22 a and 22 b are preferably about one inch in diameter.
A compressible ring 60 is insertable into the recess 30 in the shelf 28 . The ring 60 provides an interference fit to better hold a one gallon paint can in the recess 30 .
The paint can shelf 20 described above is a preferred design for a right handed painter, another embodiment for a left handed painter is a mirror image of the paint can shelf 20 . An example of a suitable material for the paint can shelf 20 is polycarbonate sold under the trademark LEXAN.
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 paint can shelf attaches to a sliding extension ladder fly section. The shelf includes two parallel arms which reach through hollow rungs of the sliding extension ladder fly section, whereby the shelf is raised and lowered with the sliding extension ladder fly section. Slides are attached to the arms on each side of the sliding extension ladder fly section and include low friction surfaces facing the fixed extension ladder section. The slides allow somewhat loose tolerances in the engagement of the arms with the ladder preventing the ladder sections from binding when the ladder is extended or lowered. | 4 |
FIELD OF THE INVENTION
This invention relates to a process utilizing a reactive exothermic liquid-inorganic solid hybrid, for the treatment of in-situ waste materials and in-process hazardous materials, including organic materials having contained therein polychlorinated biphenyls (PCBs). More specifically, this invention discloses a process which is suitable for treating and rendering inert the above-mentioned materials.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,234,485 to Bolsing discloses a method of immobilizing a contaminant comprising mixing the contaminant with a reaction partner which is capable of chemically interacting with the contaminant to form a water-insoluble reaction product. The reaction partner is mixed in the form of a hydrophobic solid preparation, which is either obtained by grinding the reaction partner with an inert material and treating it with a hydrophobic agent or a material which contains the educt or reaction product of a dispersion by chemical reaction preliminary treated with a hydrophobic agent, the mixture being conducted to form a soil or soil-like material with cohesive constituents of a clay-like structure. The Bolsing compositions may comprise stearic acid, alcohol, quicklime and water. These compositions specifically call for mixing the quicklime and water before contacting the quicklime with the waste or hazardous material. Thus, Bolsing teaches away from the present invention.
U.S. Pat. No. 4,018,679 to Bolsing (Bolsing '679) discloses a method of rendering harmless an oily waste material comprising mixing an alkaline earth metal oxide with a surface active agent which delays reaction between the alkaline earth metal oxide and water, combining the mixture with the oily material, and reacting the alkaline earth metal oxide charged with the waste material with approximately the stoichiometric amount of water to convert the alkaline earth metal oxide to the hydroxide. The alkaline earth metal oxide is preferably calcium oxide and advantageously it is also mixed with a hydrophobizing agent prior to mixture with the oily waste material. Proportions are desirably such that the end product is a solid which can be used as a lining in road construction and at dump sites. The Bolsing '679 compositions may comprise quicklime, water, a stearic acid and alcohols. Bolsing '679 does not teach or suggest using its process for breaking down PCB containing waste or hazardous material. Bolsing '679 also teaches to reduce the exothermic heat generated by including magnesium oxide with calcium oxide. On the other hand, the present invention recognizes that higher temperatures (400° to 600° F.) are optimally suited for breaking down PCB containing waste and hazardous material. Additionally, Bolsing '679 teaches that calcium hydroxide absorbs the oily waste. Conversely, in the present invention, absorption of the waste/hazardous material occurs before reaction between water and quicklime. Thus, Bolsing '679 teaches away from the present invention.
U.S. Pat. No. 5,108,647 to Bolsing ("Bolsing '647") discloses a method of dehalogenating a halogenated hydrocarbon in the presence of a nucleophilic reaction partner, comprising dispersing the halogenated hydrocarbon by chemical reaction (DCR), and dehalogenating the resulting finely dispersed reaction product by means of a strictly chemical conversion with the nucleophilic reaction partner at a temperature between ambient temperature and approximately 950° F. Bolsing '647 does not teach or suggest the coating of the quicklime with an aliphatic salt of sodium or the like for the purpose of rendering the quicklime organophilic, prior to contacting the quicklime with the halogenated hydrocarbon (waste). In fact by teaching that the halogenated hydrocarbon (waste) is contacted with untreated quicklime, Bolsing '647 teaches away from the present invention. Additionally, by teaching the use of external heating in most if not all of the disclosed examples, Bolsing '647 again teaches away from the present invention.
U.S. Pat. No. 5,186,742 to Hoffman et al., discloses a process wherein arc dust waste produced by electric arc furnaces are conducted to silos and converted to a reusable co-product by means of an addition of a special blend of high calcium and dolomitic quicklime, calcium stearate and pulverized waste paper. The mixture is pressed into compact pellets which, due to their impact integrate and improved shelf life can be pneumatically conveyed intact into storage silos for recycling of the waste electric arc flue dust into the furnace melt. Compliments of the arc-dust deemed leachable and hazardous in landfills such as zinc, lead and chromium are increased in concentration to a point where it is economical to extract them for resale. Hoffman's compositions for converting arc-dust waste to a useful product may comprise quicklime, calcium stearate and pulverized waste paper.
Japanese abstract number 58-79509 to Tashiro discloses another use of quicklime and slaked lime (an OH containing compound), in connection with a waste treatment process.
U.S. Pat. No. 4,329,090 to Teague et al. discloses a method for treating surface earth layers to achieve stabilization, strength and permeability, by slaking quicklime in a mixing tank so as to cause elevated temperatures and so as to form a hydrated lime slurry and working said slurry into the soil to be stabilized. There is no suggestion or motivation in Teague to use quicklime for the breakdown of waste or hazardous materials.
In September 1991, the United States Environmental Protection Agency published an investigative report entitled "Fate of Polychlorinated Biphenyls (PCBs) in Soil Following Stabilization with Quicklime." This report dealt with the reports of researchers on destruction of PCBs in contaminated soil by the application of quicklime. EPA observed that these research reports were based on retrospective data from site remediation programs, anecdotal information and results of one bench-scale project. EPA investigation was conducted to verify claims that use of quicklime alone can promote decomposition of PCBs. Based on this investigation, EPA concluded that the use of quicklime (as suggested by researchers), as an in-situ treatment for removal of PCBs was not supported by their findings. The following excerpts from the EPA report are telling:
Minimal evidence of PCB dechlorination was observed . . . The destruction of PCBs by application of quicklime to contaminated soil, sediment or sludge has thus not been demonstrated, either by controlled benchtop experiments or by retrospective analysis of a sample from a remediation site where the process was applied. Evidence of PCB volatilization suggests that use of reactive quicklime as an in-situ treatment may even be contraindicated due to the potential for migration of PCBs as vapor or airborne particulates . . . (emphasis supplied)
This report clearly teaches away from utilizing quicklime to break down waste or hazardous materials containing PCBs.
SUMMARY OF THE INVENTION
It is the primary object of the present invention to provide a new method for the simultaneous and stepwise treatment of in-situ waste materials and in-process hazardous materials containing PCBs or other organics.
It is yet another object of the present invention to provide a process which makes possible the utilization of heat from exothermic reactions for breaking down PCBs in particular.
It is another object of the present invention to provide a process for waste and hazardous materials treatment which lends itself to operation and successful breakdown of the PCBs at lower temperatures than possible in prior art processes.
In accordance with the present invention there is provided a method for the treatment of in-situ waste materials and in-process hazardous materials, said materials including PCBs and other organics, the method comprising the steps of: preparing a mixture comprising at least 70 weight percent quicklime, 0.1 to 10 weight percent of products of reaction between an aliphatic acid composition consisting of 50 weight percent palmitic acid, 39 weight percent stearic acid, 5 weight percent oleic acid, 2.5 weight percent margaric acid, 2.5 weight myristic acid and 1 weight percent pentadecanoic acid and an organic or inorganic OH containing substance; contacting said mixture with said waste to be treated, the weight ratio of said mixture to the dry weight of said waste ranging from 1:5 to 1:10; absorbing said materials into said mixture; adding water to said waste containing mixture, the weight of said mixture being greater than that of said water; causing an exothermic reaction between said mixture and the water thereby generating a temperature of at least 200° F.; and breaking down said waste due to said exothermic reaction by the formation of a water insoluble powder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The fundamental concepts of the present invention are as follows: a particular liquid is chosen such that when it comes into contact with a specific solid, an exothermic or heat-generating reaction occurs.
PCBs are complex organic molecules. Quicklime or calcium oxide, which is an inorganic chemical, reacts with PCBs and with other organic molecules, when rendered organophilic. This occurs when the quicklime is treated with a nucleophilic reaction partner and a catalyst. The treated quicklime is contacted with the PCB containing material (waste or hazardous), which breaks down (by conversion into water insoluble materials comprising dechlorinated biphenyls and other organics, inorganic alkali chlorides and oxychlorides), at temperatures in excess of about 200° F. The heat generating (exothermic) reaction is achieved by contacting the treated quicklime and PCB containing material (waste or hazardous) with water or other suitable liquid. Optimal reaction temperatures for the breakdown of organic compounds like PCBs would be between 400° and 600° F. Varying the water content has a definite impact upon the temperature generated. It is believed that the organophilic quicklime molecule interacts with the PCB, which then reacts at the favorable temperature conditions by forming salts, thereby being stabilized.
Conversion of the quicklime into an organophilic compound is the first step. This conversion is achieved by mixing and coating quicklime with aliphatic salts of sodium. The nucleophilic reaction partner and catalyst can be sodium hydroxide and/or sodium alkoxide. Additional reagents in some applications can be calcium monobasic phosphate, sodium metabisulfite and magnesium compounds. Sulfonated alkali phosphate and sulfite additives have also been employed to render hazardous materials non-hazardous. The combined mixture (prior to reaction with the PCB containing material) is referred to as "alkasol."
Optimum range of alkasol to water is 3 to 1 or greater. Quite possibly sodium stearate would also achieve the same effect as a combination of, for example stearic acid as the source of stearate and sodium hydroxide. This is because stearic acid and sodium hydroxide gives sodium stearate. The alkasol could comprise about 1 weight percent stearic acid (or other aliphatic salt of sodium), approximately 0-1 weight percent sodium hydroxide and the rest quicklime. Aliphatic salts of sodium can also be formed by combining acids such as stearic acid, palmitic acid, oleic acid, margaric acid, myristic acid, pentadecanoic acid, etc; and sodium hydroxide and/or sodium alkoxide.
It is essential that as much surface area as possible be provided and therefore it is preferable to grind the alkasol mixture and bring it down to a fine powder. The coarser the mixture, the less effective it is in bringing about the high temperature. However, the powder works whether it is fine or coarse. Finer powder, especially as the powder gets very, very fine, creates environmental problems associated with dust emanation. Hence, there is a happy medium between a very coarse material and an extremely fine material. Particle sizes ranging from -60 mesh to -325 mesh are acceptable. The idea behind coating the quicklime with the stearate is to prevent the quicklime from coming into direct contact with water first before absorption of the PCB containing waste/hazardous material and to make the quicklime organophilic, i.e. facilitate the absorption of organics. If the quicklime comes into contact with water, an exothermic reaction is started. The stearate retards this chemical reaction until all of the organic molecules are absorbed so that there are no organic molecules surrounding the powder if you look at the powder at a microscopic scale. All of the organic molecules are absorbed and then the water is exposed to the powder.
Examples of specific compositions which have been found to be satisfactory for providing in-situ waste treatment on in-process hazardous materials treatment and breaking down PCBs are disclosed as follows:
Table I
90-98% Quicklime (Dravo Lime Company)
0.1-10% 50 weight percent palmitic acid, 39 weight percent stearic acid, 5 weight percent oleic acid, 2.5 weight percent margaric acid,
2.5 weight myristic acid and 1 weight percent pentadecanoic acid
0.1-10% Caustic Soda (Ashland Chemical, Inc.)
Table II
70-98% Quicklime
0.1-10% 50 weight percent palmitic acid, 39 weight percent stearic acid, 5 weight percent oleic acid, 2.5 weight percent margaric acid,
2.5 weight myristic acid and 1 weight percent pentadecanoic acid
0.1-10% Caustic Soda
0-25% Sulfonated Alkali Phosphates and Sulfites.
Thus, it is apparent that there have been provided in accordance with the present invention, compositions and a method suited for treating waste/hazardous materials which contain PCBs for the breakdown of the PCBs, which fully satisfy the objects, aspects and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the appended claims. | A process utilizing a reactive exothermic liquid-inorganic solid hybrid, for the treatment of in-situ waste materials and in-process hazardous materials, including organic materials having contained therein polychlorinated biphenyls (PCBs). The process makes possible the utilization of heat from exothermic reactions for breaking down PCBs in particular. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to an apparatus for use in an orthopedic surgery, and more particularly to an apparatus for locating the interlocking intramedullary nails.
BACKGROUND OF THE INVENTION
The U.S. Pat. No. 5,474,561 of the same applicant has disclosed an all positional and universal guiding device for interlocking intramedullary nail. Under such a prior art, the applicant devotes himself and creates a further development and precision apparatus for locating interlocking intramedullary nails.
The interlocking intramedullary nails are often used in treatment of deformities, diseases, and injuries of bones, such as humerus, femur, tibia, etc. The interlocking intramedullary nails are used in conjunction with the fixation nails for the rehabilitation of the deformed bone. Such restorative operation is often complicated by the fact that there are a variety of interlocking intramedullary nails, which are different in specification and are made by various manufacturers.
It is technically difficult to implant an interlocking intramedullary nail with precision. In order to minimize the technical difficulty that is involved in the implanting of the interlocking intramedullary nail, the X-ray machine is often used to help the surgeon to align the nail with the threaded hole. It is conceivable that the constant exposure to the X-rays is hazardous to the health of the surgeon.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide an adjustable apparatus enabling the interlocking intramedullary nails of various specifications to be aligned with the near end and the far end threaded holes without the use of the X-ray machine.
The features and the advantages of the present invention will be more readily understood upon a thoughtful deliberation of the following detailed description of the present invention with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exploded view of the present invention.
FIG. 2 shows a perspective view of the present invention in combination.
FIG. 3 shows a schematic view of the inclined near end threaded hole of the present invention.
FIG. 4 shows a schematic view of another near end threaded hole of the present invention.
FIG. 5 shows a schematic view of the far end threaded hole of the present invention.
FIG. 6 shows a schematic view of a locating embodiment of another near end threaded hole of the present invention.
FIG. 7 shows a schematic view of a drilling embodiment of another near end threaded hole of the present invention.
FIG. 8 shows a schematic view of the embodiment of the inclined near end threaded hole of the present invention.
FIG. 9 shows a schematic view of a locating embodiment of the far end threaded hole of the present invention.
FIG. 10 shows a schematic view of a drilling embodiment of the far end threaded hole of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 and 2, the present invention comprises a curved main body 10 and a vertical seat 11 , which is perpendicular to the bone nail and is provided with and inner recessed hole 12 and a plurality of fastening holes 13 . The main body 10 is provided with a parallel seat 14 which is parallel to the bone nail and is provided with a long slide slot 15 and a swaying seat 16 which is in turn provided with a locking hole 17 . The locking hole 17 is provided at the outer end thereof with a protruded pillar 18 . The inner recessed hole 12 of the vertical seat 11 of the main body 10 is provided with an extension seat 20 which is provided with an expandable rod 21 having a plurality of fitting holes 22 corresponding to the locking hole 13 . The extension seat 20 is provided at other end thereof with a carrying seat 23 which is provided in the midsegment thereof with a through hole 24 which is provided at the bottom end thereof with a locating block 25 projecting therefrom. The extension seat 20 is further provided with a near end inclined hole 26 as desired. The locking hole 13 end of the main body 10 is provided with two threaded rods 27 to cooperate with the fitting hole 22 . In light of various bone nail designs, the carrying seat 23 is provided at the bottom end thereof with a rotary connection block 30 which is in turn provided at the bottom end with an orientation locating block 32 for connecting the threaded rod 35 end of a nail connection rod 34 . The parallel seat 14 is provided with two slide blocks 40 fastened thereto. The slide block 40 is provided with two retaining holes 41 in cooperation with the slide slot 15 . The slide block 40 is provided in one side with a fixation thread 42 to cooperate with a threaded rod 43 . The swaying seat 16 is provided with an adjustment swing arm 50 which is provided with an axial hole 51 to cooperate with the locking hole 17 so as to set up a threaded rod 52 . The adjustment swing arm 50 is provided with a slide hole 53 and a locking hole 54 to cooperate a threaded rod 55 . The protruded pillar 18 of the main body 10 is provided with an arcuate restriction slot 56 . The adjustment swing arm 50 is provided at the bottom end thereof with an adjustment block 60 extending therefrom and having a locating slide shaft 61 to cooperate the slide hole 53 of the adjustment swing arm 50 . The locating slide shaft 61 is provided at one end with a retaining face 62 . The adjustment block 60 is provided at the front end with an axial hole 63 which is provided at the outer end with a recessed restriction slot 64 . The axial hole 63 of the adjustment block 60 is connected with the locking hole 72 of the rotary seat 71 of a slide seat 70 by a threaded rod 65 . The locking hole 72 is provided at the outer end with a protruded pillar 73 to cooperate with the restriction slot 64 . The slide seat 70 is provided with a slide through hole 74 and a fitting hole 75 . A threaded rod 77 is provided to fasten the locking hole 76 of the slide hole 74 in which an adjustment rod 80 is received. An opening hole 81 is corresponding to the fitting hole 75 of the slide seat 70 . The adjustment rod 80 is provided at the front end with a fitting hole 82 . Finally, the near end inclined hole 26 , the retaining hole 41 , the fitting holes 75 , 82 are provided with a guide rod 36 or drilling guide sleeve 37 .
As shown in FIGS. 3-5, in conjunction with FIGS. 6-10, the component parts of the present invention can be easily separated or combined. They can be stored separately in an orderly manner. They can be stored separately in an orderly manner. They can be put together as required in cooperation with the interlocking intramedullary nails of various specifications.
As shown in FIG. 3, in light of the near end threaded hole of the interlocking intramedullary nail being of an inclined construction, only the extension seat 20 is called for such that the locating block 25 of the extension seat 20 is fitted with the interlocking intramedullary nail of an appropriate specification, and that it is fastened with the threaded rod 35 of the nail connection rod 34 . The near end inclined hole 26 is provided with the drilling guide sleeve 37 for drilling the near end threaded hole, as shown in FIG. 8 . The expandable rod 21 of the extension seat 20 can be cooperated with the body size of a patient such that it can be fixed in the inner recessed hole 12 by two threaded rods 27 .
As shown in FIG. 4, in light of the near end threaded hole of the interlocking intramedullary nail being perpendicular to the interlocking intramedullary nail end, the slide block 40 is fastened with the parallel seat 14 of the main body 10 after being fastened onto humerus, femur, or tibia. The interlocking intramedullary nails of various specifications are thus fastened by means of two guide rods 36 and the threaded rod 43 , as shown in FIG. 6 . The near end threaded holes of various intervals of interlocking intramedullary nails of various brands are thus located. Upon completion of the implanting of the nails onto humerus, femur, or tibia, the drilling guide sleeve 37 is connected to facilitate the work of drilling the near end threaded hole, as shown in FIG. 7 .
As shown in FIG. 5, the far end threaded hole is located by the present invention. Upon completion of the fastening of the interlocking intramedullary nail, the adjustment swing arm 50 of an appropriate length is selected and then fastened by the threaded rod 55 . The far end threaded hole member is formed of the adjustment block 60 , the slide seat 70 , and the adjustment rod 70 . The far end threaded holes of the interlocking intramedullary nails are connected by two guide rods 36 in conjunction with the fitting holes 75 and 82 . As the threaded rods 65 and 52 are unfastened, the protruded pillars 18 and 73 are located in the restriction slot 56 , 64 respectively. The present invention is capable of cooperating with the curvature of the interlocking intramedullary nails. Upon completion of the fastening of the threaded rods 77 , 65 , 55 , and 52 , the parallel locating of the far end threaded holes is thus attained, as shown in FIG. 9 . After the implantation of the interlocking intramedullary nail into femur, tibia, or humerus, the drilling guide sleeve 37 is fastened to facilitate the work of drilling the far end threaded hole, as shown in FIG. 10 . In light of the interlocking intramedullary nails being various in length, it is necessary to unfasten the threaded rod 55 so as to adjust the relative positions of the locating slide shaft 61 and the slide hole 53 of the adjustment swing arm 50 . For the purpose of locating the far end threaded holes of various brands, the threaded rod 77 is first unfastened so as-to adjust the two guide rods 36 in relation to the hole interval of various far end threaded holes of the interlocking intramedullary nails. The locating of the far end threaded holes of various brands can be also attained by adjusting the sliding distance of the adjustment rod 80 in the slide hole 74 of the slide seat 70 . Finally, the threaded rod 77 is fastened to conclude the adjusting of the hole interval of the far end threaded holes of various brands.
Depending on the body size of a patient, the adjustment of the near end and the far end threaded holes of the interlocking intramedullary nails of various specifications is attained by changing the adjustment swing arm 50 and the adjustment block 60 . The locating blocks 25 of various specifications can be adjusted by means of the expandable rod 21 of the extension seat 20 . According to the bone size of the patient, the locating of the threaded holes, the drilling of the threaded holes, and the fastening of the threaded holes can be done by adjusting the distance between the deformed bone and the horizontal seat 14 of the main body 10 , without the help of the X-ray machine. | An apparatus for locating interlocking intramedullary nails comprises a slide device which is disposed at the near end of the nails and is capable of adjustment in various directions. The slide device is provided with a locking structure, a locating rod, or drilling guide sleeve. The relative positions of the near end and the far end threaded holes of the interlocking intramedullary nails of various hole intervals and specifications are adjusted by the slide device in accordance with the body size of a patient under treatment. The drilling position of the drilling guide sleeve can be attained with precision and speed. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to the production of metal carbides. More particularly, the present invention relates to producing metal carbides from several carbon materials through a single step process wherein a metal oxide is combined with a carbon source and converted to the metal carbide utilizing a novel induction heating process.
[0006] 2. General Background of the Invention
[0007] In the present state of the art, metal carbides are typically produced in a multiple step process in which carbon from carbon containing gases is first pyrolytically deposited onto a metal oxide. The resulting composite is subsequently reduced in an inert atmosphere by resistance heating to high temperatures of 1200° C. or greater, over a several hour period to obtain the metal carbide.
[0008] One prior art reference, included herein through the Information Disclosure Statement, teaches a single step process (J. Mat. Sci 33 (1998) 1049-1055. However, this reference also used resistance heating at extended reaction times. In these prior art procedures, the particle sizes of the metal carbide obtained are increased in comparison to those of the starting materials, and conversion is less than complete as evidenced by the presence of residual oxygen, as shown by EDS, in the resulting product.
[0009] Throughout this application the following terms shall be defined as follows:
1. “morphology” is used to describe the size and shape of carbonaceous reactants in metal carbide products. 2. “TEM”—(Transmission Electron Microscopy) is used herein to provide depictions of morphology. 3. “XRD”—(X-Ray Diffraction) is used herein to define crystal structure and phase. 4. STEMEDS, EDS—(Electron Diffraction Spectroscopy) is used herein for microscale elemental analysis.
[0014] In applicant's experimental process, applicant was expecting that the results would be a metal carbide coating over carbon core. The unexpected results obtained, as will be explained further, was a composition of wholly metal carbide products retaining the morphology of the carbon precursors.
BRIEF SUMMARY OF THE INVENTION
[0015] In the present invention, there is provided a process for synthesizing metal carbides, through a single step process, wherein oxides of different metals, including, but not limited to Si, Ti, W, Hf, Zr, V, Cr, Ta, B, Nb, Al, Mn, Ni, Fe, Co, and Mo, were physically mixed with different, spherical (20 nm) or fibrous (60 nm) nano structured carbon precursors and inductively heated to a temperature range from 900-1900° C. where the metal oxide reacts with the carbon to form different metal carbides. The process retains the original morphology of the starting carbon precursor in the resultant metal carbides. The metal nano-carbides _produced are also highly crystalline. Most of these particles are single crystals of metal carbides. The conversion on this process is more than 80% to metal carbides, with the balance comprising unconverted excess carbon.
[0016] In yet another application, nanostructured SiC (and other carbides) would be utilized as a discontinuous reinforcement agent in aluminum and other alloys. In doing so, the nanostructured SiC would be nano-sized, spherical carbides which would minimize stress concentrations. There would also be provided branched nano-sized carbide aggregates which would be the same shape as medium or high structure carbon black aggregates, which would increase crack path tortuosity and would trap cracks.
[0017] Therefore, it is a principal object of the present invention to produce highly crystalline filamentateous nano metal carbides;
[0018] It is a further object of the present invention to produce nano metal carbides whereby the morphology of the carbon precursor in the resultant metal carbide is retained;
[0019] It is a further object of the present invention to provide a process for producing metal carbides through the use of an induction heating process;
[0020] It is a further object of the present invention to produce metal carbides completely converting MOx to metal carbides as evidenced by the absence of O in EDS and of any other phase in XRD;
[0021] It is a further object of the present invention to provide a semi-continuous or continuous process for production of metal carbides;
[0022] It is a further object of the present invention to provide a metal carbide product which can be used wherever prior art metal carbides are applied;
[0023] It is a further object of the present invention to provide metal carbides which are envisioned to replace noble metal in hydrogenation catalysts;
[0024] It is a further object of the present invention to provide nano-filament carbides with utility in specific nano-scale applications in which size requirements preclude the use of prior art metal carbides; and
[0025] It is a further object of the present invention to provide metal carbide products which would have applications in, but not limited to, high temperature thermoelectric devices, quantum wells, optoelectronic devices, semiconductors, body armour, vehicle armour, catalysts, discontinuous reinforcement agents, structural reinforcement, improving wear resistance, provide resistance to corrosion, enhance high temperature stability, provide radiation resistance, and provide increased thermal conductivity.
[0026] It is a further object of the present invention to provide metal carbide products wherein the discontinuous reinforcement agent would be present in aluminum and other alloys to minimize stress concentrations and branched nano-sized carbon aggregates would increase crack path tortuosity and would trap cracks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0028] FIG. 1 depicts the general chemistry and conditions involved in the metal carbide production in the present invention;
[0029] FIG. 2 is a schematic representation of the metal carbide production apparatus of the present invention;
[0030] FIG. 3 is a schematic representation of the metal carbide production apparatus for undertaking a semi-continuous process for producing and collecting metal carbides in the present invention;
[0031] FIG. 4 is a TEM showing the morphology of the precursor carbon black used in the process of the present invention;
[0032] FIG. 5 is a TEM of B 4 C synthesized from carbon black in the present invention;
[0033] FIG. 6 is a TEM showing the morphology of the precursor carbon nanofibers used in the process of the present invention;
[0034] FIG. 7 is a TEM of molybdenum carbide produced by the process of the present invention;
[0035] FIG. 8 is a TEM of SiC crystals on the surface of SiC fiber produced in the process of the present invention;
[0036] FIG. 9 is a TEM of TiC produced in the process of the present invention;
[0037] FIG. 10 comprises XRD spectra of metal carbides derived from carbon black in the process of the present invention;
[0038] FIG. 11 comprises XRD spectra of metal carbides derived from carbon nanofibers in the process of the present invention; and
[0039] Table 1 provides the identification of major and minor phases in the XRD spectra of FIGS. 10 and 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] In the production of metal carbides from carbon materials through a single step process, reference is made to the FIGS. 1-11 and Table 1. As indicated earlier, overall the present invention relates to a synthesis process for producing, for example, silicon, titanium and molybdenum carbides, among others. The process comprises a single step, wherein oxides of different metals, for example Si, Ti, W, Hf, Zr, V, Cr, Ta, B, Nb, Al, Mn, Ni, Fe, Co, and Mo, are physically mixed with different spherical or filamentateous nanostructure carbons. The spherical carbon particle diameter is in the range of 8-200 nm, while the filamentateous carbon diameter is in the range of 1-200 nm. The mixture is inductively heated to a certain temperature range between 900 and 1900° C. so that the metal oxide reacts with the carbon to form different metal carbides. In the use of this process, the original morphology of the carbon precursor is maintained in the resultant metal carbides. The carbides produced are highly crystalline. The conversion of this process is more than 80% to metal carbides with the balance comprising unconverted excess carbon.
[0041] What follows are the experimental examples of combining Silicon Oxide with the nanocarbon precursor in Example 1; Titanium Oxide with the nanocarbon precursor in Example 2; Molybdenum Oxide with the nanocarbon precursor in Example 3; and Boron Oxide with the nanocarbon precursor in Example 4.
EXPERIMENTAL EXAMPLES
Example One
SiO 2 +3C−→SiC+2CO
[0042] Silicon carbide powders were synthesized by using 10 g of silicon dioxide and 6 g of nanocarbon as precursor. The SiO 2 powder had an average particle size of about 40 um and a specific surface area of 5 m2/g, while the carbon sources were either a carbon black (CDX975, 253 m2/g, with an average particle size 21 nm) or a filamentous nanocarbon (68.5 m2/g with an average diameter of 70 nm). Initially, both carbon source and silicon dioxide were physically mixed using either a spatula or a ball mill, until well blended. The mixture was then placed in a graphite crucible and placed inside of a quartz vessel located within an induction coil. The vessel was purged with Ar gas with a flow of 1 SLM. After 30 min of purging, the temperature of the graphite crucible was increased to 1400° C. over 30 min and held at the desired temperature for <15 min. The graphite crucible was then cooled under Ar flow. An XRD pattern of the resulting sample showed that the particles of the powder formed were hexagonal single phase silicon carbide particles. Transmission electron microscopy showed a particle size range of 20-100 nm for the product derived from CB, while the filamentous nanocarbon completely converted into Silicon carbide of morphology matching that of the precursor carbon. Thermogrametric analysis (to remove residual carbon) of the Silicon carbides produced herein showed the conversion about 95%. STEMEDS verified that the silicon carbide particles were of a very high purity.
Example Two
TiO 2 +3C−→TiC+2CO
[0043] Titanium carbide powders were synthesized by using 13.33 g of titanium dioxide and 6 g of nanocarbon as precursor. The TiO2 powder had an average particle size of about 32 nm and a specific surface area of 45 m2/g, while the carbon sources were either a carbon black (CDX975, 253 m2/g, with an average particle size 21 nm) or a filamentous nanocarbon (68.5 m2/g with an average diameter of 70 nm). Initially, both carbon source and titanium dioxide were physically mixed using either a spatula or a ball mill, until well blended. The mixture was then placed in a graphite crucible and placed inside of a quartz vessel located within an induction coil. The vessel was purged with Ar gas with a flow of 1 SLM. After 30 min of purging, the temperature of the graphite crucible was increased to 1400° C. over 30 min and held at the desired temperature for <15 min. The graphite crucible was then cooled under Ar flow. An XRD pattern of the resulting sample showed that the particles of the powder formed were cubic single phase titanium carbide particles. Transmission electron microscopy showed an particle size range of 20-100 nm for the product derived from CB, while the filamentous nanocarbon completely converted into titanium carbide of morphology matching that of the precursor carbon. STEMEDS verified that the titanium carbide particles were of a very high purity.
Example Three
Mo 2 O 3 +4C−→MO 2 C+3CO
[0044] Molybdenum carbide powders were synthesized by using 24 g of molybdenum dioxide and 6 g of nanocarbon as precursor. The Mo 2 O 3 powder had an average particle size of about 20-40 nm and a specific surface area of 48 m2/g, while the carbon sources were either a carbon black (CDX975, 253 m2/g, with an average particle size 21 nm) or a filamentous nanocarbon (68.5 m2/g with an average diameter of 70 nm). Initially, both carbon source and Molybdenum oxide were physically mixed using either a spatula or a ball mill, until well blended. The mixture was then placed in a graphite crucible and placed inside of a quartz vessel located within induction coil. The vessel was purged with Ar gas with a flow of 1 SLM. After 30 min of purging, the temperature of the graphite crucible was increased to 1350° C. over 30 min and held at the desired temperature for <15 min. The graphite crucible was then cooled under Ar flow. An XRD pattern of the resulting sample showed that the particles of the powder formed were hexagonal single phase Molybdenum carbide particles. Transmission electron microscopy showed an particle size range of 20-100 nm for the product derived from CB, while the filamentous nanocarbon completely converted into Molybdenum carbide of morphology matching that of the precursor carbon. STEMEDS verified that the Molybdenum carbide particles were of a very high purity.
Example Four
2B 2 O 3 +7C−→B 4 C+6CO
[0045] Boron carbide powders were synthesized by using 14 G of boron oxide and 8.4 g of nanocarbon as precursor. The B 2 O 3 powder had an average particle size of about 40 um and a specific surface area of 5 m2/g, while the carbon sources were either a carbon black (CDX975, 253 m2/g, with an average particle size 21 nm) or a filamentous nanocarbon (68.5 m2/g, with an average diameter of 70 nm). Initially, both carbon source and Boron oxide were physically mixed using either a spatula or a ball mill, until well blended. The mixture was then placed in a graphite crucible and placed inside of a quartz vessel located within induction coil. The vessel was purged with Ar gas with a flow of 1 SLM. After 30 min of purging, the temperature of the graphite crucible was increased to 1300° C. over 30 min and held at the desired temperature for <15 min. The graphite crucible was cooled under Ar flow. An XRD pattern of the resulting sample showed that the particles of the powder formed were hexagonal single phase boron carbide particles. Transmission electron microscopy showed an particle size range of 20-100 nm for the product derived from CB, while the filamentous nanocarbon completely converted into boron carbides of morphology matching that of the precursor carbon.
[0046] Turning now to the FIGS. 1 through 11 and Table 1: FIG. 1 , depicts the chemistry and reaction conditions associated with the present invention: xC+M y O (x-1) →M y C+(x-1)CO, wherein M is selected from a group including, but not limited to, Si, B, Ta, Zr, Cr, V, W, Hf, Ti and Mo. The reaction requires that a uniform mixture of metal oxide and nanocarbons be heated inductively at 900° to 1900° C. and held thereat for 1-30 min. under inert gas flow.
[0047] Batch and semicontinuous means for producing the metal carbides, set forth in FIG. 1 , are depicted schematically in FIGS. 2 and 3 respectively. The apparatus depicted in FIG. 2 was employed in the Examples 1 through 4.
[0048] FIG. 2 provides a schematic representation for the metal carbide experimental process as practised in a batch mode. In FIG. 2 there is illustrated argon gas (arrow 12 ) that enters into a quartz reactor 14 , of the type commonly known in the industry, which contains a graphite crucible 16 , surrounded by an induction coil 18 . A mixture of Metal oxide and carbon is placed within the graphite crucible 16 at 20 . The mixture is then heated via the induction coil 18 to a temperature between 900 and 1900° C. The argon gas is vented out (arrow 22 ) and the resultant metal carbide remains in the crucible 16 for collection.
[0049] FIG. 3 provides a schematic representation of the semi-continuous or continuous production of metal carbides. As depicted, metal carbide powders can be synthesized semi-continuously by using a quartz reactor 14 . The quartz reactor 14 includes a graphite crucible 16 which would contain the metal oxide and carbon mixtures at 20 . There would also be included the induction coil 18 , surrounding the quartz reactor, for heating the mixture as described in FIG. 2 . However, in the semi-continuous process illustrated in FIG. 3 , there is provided a feeder 30 which contains the premixed metal oxide and carbon precursors at 31 . The argon gas (arrow 12 ) is introduced into the mixture of the metal oxide and carbon sources at 31 in feeder 30 , and the mixture is pneumatically conveyed thereby into graphite crucible 16 , where the mixture is heated by the induction coil 18 to the desired temperature of 900 to 1900° C. and held thereat for 1-30 min. There is provided a collector 34 , to which the resultant metal carbides can be conveyed from the crucible 16 , via vacuum line 35 , for collection. The quartz reactor is purged with argon gas 12 with a flow of 1 SLM. This process can be repeated to achieve semi-continuous production of metal carbides without opening the reactor system.
[0050] FIGS. 4 through 9 are transmission electron micrographs which depict the morphologies of the carbon reactants ( 4 , 6 ) and carbide products ( 5 , 7 - 9 ) representative of those used and produced in examples 1-4 preceding.
[0051] FIG. 4 is a TEM depicting the morphology of the nanocarbon black that is used as the precursor in the described experiment. This carbon black is CDX-975 (Columbian Chemicals Co.) With an average particle size of 21 nm.
[0052] FIG. 5 is a TEM depicting the Boron Carbide (B 4 C) produced as described in Example 4 from the carbon black depicted in FIG. 4 .
[0053] FIG. 6 is a TEM depicting the carbon nanofiber precursor as used in experiments 1-4. This material has a nitrogen surface area of 68 m 2 /g and an average fiber diameter of 70 nm.
[0054] FIG. 7 is a TEM of molybdenum carbide fibers produced as described in example 3 from the carbon nanofiber depicted in FIG. 6 . Note the presence of Mo 2 C crystallites adhered to the fiber surface.
[0055] FIG. 8 depicts a TEM of SiC fibers produced as described in example 1 from the carbon nanofiber depicted in FIG. 6 . STEM/EDAX analysis showed no residual oxygen to be present in this product, indicating complete conversion to the carbide.
[0056] FIG. 9 is a TEM of TiC fibers produced as described in Example 2 from the carbon nanofiber depicted in FIG. 6 . STEM/EDAX analysis showed no residual oxygen to be present, in this product, indicating complete conversion to the carbide.
[0057] Turning now to Table 1, entitled “Identification of Major and Minor Phases of XRD Spectra,” XRD analysis was also carried out on the samples from experiments 1-4. The three samples (A-31077, A-31078, and A-31079) were different metal carbides derived from carbon black (CDX975, A027276), while samples A-31080, A-31081 and A-31082 were similar metal carbides derived from carbon nanofibers (sample A-30887). XRD spectra from the metal carbides derived from CB are shown in FIG. 10 , while the spectra from those derived from fibers are shown in FIG. 11 . Matching of peaks reveals no difference in the carbide phases produced from the two starting materials. A listing of major and minor component peaks in the XRD spectra is given in Table 1. These results demonstrate the essentially complete conversion of the starting materials to their respective carbides.
[0058] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A metal carbide composition and a process for synthesizing metal carbides, through a single step process, wherein oxides of different metals, including, but not limited to Si, Ti, W, Hf, Zr, V, Cr, Ta, B, Nb, Al, Mn, Ni, Fe, Co, and Mo were physically mixed with spherical or filamentateous nano structured carbon, and inductively heated to a certain temperature range (900-1900° C.) where the metal oxide reacts with carbon to form different metal carbides. The process retains the original morphology of the starting carbon precursor in the resultant metal carbides. This method also produces highly crystalline metal nano-carbides. The metal carbide products would have applications in high temperature thermoelectric devices, quantum wells, optoelectronic devices, semi-conductors, body armour, vehicle armour, catalysts, and as discontinuous reinforced agents in metal such as aluminum and other alloys. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 11/257,379, filed Oct. 24, 2005, which is hereby incorporated by reference in its entirety herein. In addition, this application was filed on the same day as the following application with the same title, ______ [EXP.017A2DV1], which is also hereby incorporated by reference in its entirety herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This disclosure generally relates to financial data processing, and in particular it relates to credit scoring, customer profiling, consumer behavior analysis and modeling.
[0004] 2. Description of the Related Art
[0005] It is axiomatic that consumers will tend to spend more when they have greater purchasing power. The capability to accurately estimate a consumer's spend capacity could therefore allow a financial institution (such as a credit company, lender or any consumer services companies) to better target potential prospects and identify any opportunities to increase consumer transaction volumes, without an undue increase in the risk of defaults. Attracting additional consumer spending in this manner, in turn, would increase such financial institution's revenues, primarily in the form of an increase in transaction fees and interest payments received. Consequently, a consumer model that can accurately estimate purchasing power is of paramount interest to many financial institutions and other consumer services companies.
[0006] A limited ability to estimate consumer spend behavior from point-in-time credit data has previously been available. A financial institution can, for example, simply monitor the balances of its own customers' accounts. When a credit balance is lowered, the financial institution could then assume that the corresponding consumer now has greater purchasing power. However, it is oftentimes difficult to confirm whether the lowered balance is the result of a balance transfer to another account. Such balance transfers represent no increase in the consumer's capacity to spend, and so this simple model of consumer behavior has its flaws.
[0007] In order to achieve a complete picture of any consumer's purchasing ability, one must examine in detail the full range of a consumer's financial accounts, including credit accounts, checking and savings accounts, investment portfolios, and the like. However, the vast majority of consumers do not maintain all such accounts with the same financial institution, and the access to detailed financial information from other financial institutions is restricted by consumer privacy laws, disclosure policies, and security concerns.
[0008] There is limited and incomplete consumer information from credit bureaus and the like at the aggregate and individual consumer levels. Since balance transfers are nearly impossible to consistently identify from the face of such records, this information has not previously been enough to obtain accurate estimates of a consumer's actual spending ability.
[0009] Accordingly, there is a need for a method and apparatus for modeling consumer spending behavior which addresses certain problems of existing technologies.
SUMMARY OF THE DISCLOSURE
[0010] It is an object of the present disclosure, therefore, to introduce a method for modeling consumer behavior and applying the model to both potential and actual customers (who may be individual consumers or businesses) to determine their spend over previous periods of time (sometimes referred to herein as the customer's size of wallet) from tradeline data sources. The share of wallet by tradeline or account type may also be determined. At the highest level, the size of wallet is represented by a consumer's or business' total aggregate spending, and the share of wallet represents how the customer uses different payment instruments.
[0011] In various embodiments, a method and apparatus for modeling consumer behavior includes receiving individual and aggregated consumer data for a plurality of different consumers. The consumer data may include, for example, time series tradeline data, consumer panel data, and internal customer data. One or more models of consumer spending patterns are then derived based on the consumer data for one or more categories of consumer. Categories for such consumers may be based on spending levels, spending behavior, tradeline user and type of tradeline.
[0012] In various embodiments, a method and apparatus for estimating the spending levels of an individual consumer is next provided, which relies on the models of consumer behavior above. Size of wallet calculations for individual prospects and customers are derived from credit bureau data sources to produce outputs using the models.
[0013] Balance transfers into credit accounts are identified based on individual tradeline data according to various algorithms, and any identified balance transfer amount is excluded from the spending calculation for individual consumers. The identification of balance transfers enables more accurate utilization of balance data to reflect consumer spending.
[0014] Using results of the size of wallet calculations, together with a customer's known spending using a given payment instrument, such as a given credit card, allows for a calculation of the given payment instrument's share of wallet, or percentage of total spend, for the customer. An electronic notification of the share of wallet information may be transmitted to an interested party, such as to the issuer of the credit card.
[0015] When consumer spending levels and share of wallet levels are reliably identified in this manner, customers may be categorized to more effectively manage the customer relationship and increase the profitability therefrom. As one example, the information may be used to determine whether to offer an incentive and/or to select a type of incentive to be offered to the customer to encourage the customer to more frequently use the payment instrument or to transfer balances to the payment instrument.
[0016] For purposes of summarizing embodiments of the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such aspects, advantages, or novel features will be embodied in any particular embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Further aspects of the present disclosure will be more readily appreciated upon review of the detailed description of its various embodiments, described below, when taken in conjunction with the accompanying drawings, of which:
[0018] FIG. 1 is a block diagram of an exemplary financial data exchange network over which the processes of the present disclosure may be performed;
[0019] FIG. 2 is a flowchart of an exemplary consumer modeling process performed by the financial server of FIG. 1 ;
[0020] FIG. 3 is a diagram of exemplary categories of consumers examined during the process of FIG. 2 ;
[0021] FIG. 4 is a diagram of exemplary subcategories of consumers modeled during the process of FIG. 2 ;
[0022] FIG. 5 is a diagram of financial data used for model generation and validation according to the process of FIG. 2 ;
[0023] FIG. 6 is a flowchart of an exemplary process for estimating the spend ability of a consumer, performed by the financial server of FIG. 1 ;
[0024] FIG. 7-10 are exemplary timelines showing the rolling time periods for which individual customer data is examined during the process of FIG. 6 ; and
[0025] FIG. 11-19 are tables showing exemplary results and outputs of the process of FIG. 6 against a sample consumer population.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] As used herein, the following terms shall have the following meanings. A trade or tradeline refers to a credit or charge vehicle issued to an individual customer by a credit grantor. Types of tradelines include bank loans, credit card accounts, retail cards, personal lines of credit and car loans/leases. For purposes herein, use of the term credit card shall be construed to include charge cards, except as specifically noted. Tradeline data describes the customer's account status and activity, including, for example, names of companies where the customer has accounts, dates such accounts were opened, credit limits, types of accounts, balances over a period of time, and summary of payment histories. Tradeline data is generally available for the vast majority of actual consumers. Tradeline data, however, does not include individual transaction data, which is largely unavailable because of consumer privacy protections. Tradeline data may be used to determine both individual and aggregated consumer spending patterns, as described herein.
[0027] Consumer panel data measures consumer spending patterns from information that is provided by, typically, millions of participating consumer panelists. Such consumer panel data available through various consumer research companies such as COMSCORE. Consumer panel data may typically include individual consumer information such as credit risk scores, credit card application data, credit card purchase transaction data, credit card statement views, tradeline types, balances, credit limits, purchases, balance transfers, cash advances, payments made, finance charges, annual percentage rates, and fees charged. Such individual information from consumer panel data, however, is limited to those consumers who have participated in the consumer panel, and so such detailed data may not be available for all consumers.
[0028] Technology advances have made it possible to store, manipulate, and model large amounts of time series data with minimal expenditure on equipment. As will now be described, a financial institution may leverage these technological advances in conjunction with the types of consumer data presently available in the marketplace to more readily estimate the spend capacity of potential and actual customers. A reliable capability to assess the size of a consumer's wallet is introduced in which aggregate time series and raw tradeline data are used to model consumer behavior and attributes, and to identify categories of consumers based on aggregate behavior. The use of raw trade-line time series data, and modeled consumer behavior attributes, including but not limited to, consumer panel data and internal consumer data, allows actual consumer spend behavior to be derived from point-in-time balance information.
[0029] In addition, the advent of consumer panel data provided through internet channels provides continuous access to actual consumer spend information for model validation and refinement. Industry data, including consumer panel information having consumer statement and individual transaction data, may be used as inputs to the model and for subsequent verification and validation of its accuracy. The model is developed and refined using actual consumer information with the goals of improving the customer experience and increasing billings growth by identifying and leveraging increased consumer spend opportunities.
[0030] A credit provider or other financial institution may also make use of internal proprietary customer data retrieved from its stored internal financial records. Such internal data provides access to even more actual customer spending information, and may be used in the development, refinement and validation of aggregated consumer spending models, as well as verification of the models' applicability to existing individual customers on an ongoing basis.
[0031] While there has long been marketplace interest in understanding spend to align offers with consumers to and assign credit line size, the holistic approach of using a size of wallet calculation across customers' lifecycles (that is, acquisitions through collections) has not previously been provided. The various data sources outlined above provide the opportunity for unique model logic development and deployment, and as described in more detail in the following, various categories of consumers may be readily identified from aggregate and individual data. In certain embodiments of the processes disclosed herein, the models may be used to identify specific types of consumers, nominally labeled ‘transactors’ and ‘revolvers,’ based on aggregate spending behavior, and to then identify individual customers and prospects that fall into one of these categories. Consumers falling into these categories may then be offered commensurate purchasing incentives based on the model's estimate of consumer spending ability.
[0032] Referring now to FIGS. 1-19 , wherein similar components of the present disclosure are referenced in like manner, various embodiments of a method and system for estimating the purchasing ability of consumers will now be described in detail.
[0033] Turning now to FIG. 1 , there is depicted an exemplary computer network 100 over which the transmission of the various types of consumer data as described herein may be accomplished, using any of a variety of available computing components for processing such data in the manners described below. Such components, may include an institution computer 102 , which may be a computer, workstation or server, such as those commonly manufactured by IBM, and operated by a financial institution or the like. The institution computer 102 , in turn, has appropriate internal hardware, software, processing, memory and network communication components that enables it to perform the functions described herein, including storing both internally and externally obtained individual or aggregate consumer data in appropriate memory and processing the same according to the processes described herein using programming instructions provided in any of a variety of useful machine languages.
[0034] The institution computer 102 may in turn be in operative communication with any number of other internal or external computing devices, including for example components 104 , 106 , 108 , and 110 , which may be computers or servers of similar or compatible functional configuration. These components 104 - 110 may gather and provide aggregated and individual consumer data, as described herein, and transmit the same for processing and analysis by the institution computer 102 . Such data transmissions may occur, for example, over the Internet or by any other known communications infrastructure, such as a local area network, a wide area network, a wireless network, a fiber-optic network, or any combination or interconnection of the same. Such communications may also be transmitted in an encrypted or otherwise secure format, in any of a wide variety of known manners.
[0035] Each of the components 104 - 110 may be operated by either common or independent entities. In one exemplary embodiment, which is not to be limiting to the scope of the present disclosure, one or more such components 104 - 110 may be operated by a provider of aggregate and individual consumer tradeline data, an example of which includes services provided by EXPERIAN. Tradeline level data preferably includes up to twenty-four months or more of balance history and credit attributes captured at the tradeline level, including information about accounts as reported by various credit grantors, which in turn may be used to derive a broad view of actual aggregated consumer behavioral spending patterns.
[0036] Alternatively, or in addition thereto, one or more of the components 104 - 110 may likewise be operated by a provider of individual and aggregate consumer panel data, such as commonly provided by COMSCORE. Consumer panel data provides more detailed and specific consumer spending information regarding millions of consumer panel participants, who provide actual spend data to collectors of such data in exchange for various inducements. The data collected may include any one or more of: credit risk scores, online credit card application data, online credit card purchase transaction data, online credit card statement views, credit trade type and credit issuer, credit issuer code, portfolio level statistics, credit bureau reports, demographic data, account balances, credit limits, purchases, balance transfers, cash advances, payment amounts, finance charges, annual percentage interest rates on accounts, and fees charged, all at an individual level for each of the participating panelists. In various embodiments, this type of data is used for model development, refinement, and verification. This type of data is further advantageous over tradeline level data alone for such purposes, since such detailed information is not provided at the tradeline level. While such detailed consumer panel data can be used alone to generate a model, it may not be wholly accurate with respect to the remaining marketplace of consumers at large without further refinement. Consumer panel data may also be used to generate aggregate consumer data for model derivation and development.
[0037] Additionally, another source of inputs to the model may be internal spend and payment history of the institution's own customers. From such internal data, detailed information at the same level of specificity as the consumer panel data may be obtained and used for model development, refinement and validation, including a categorization of consumers based on identified transactor and revolver behaviors.
[0038] Turning now to FIG. 2 , there is depicted a flowchart of an exemplary process 200 for modeling aggregate consumer behavior in accordance with the present disclosure. The process 200 commences at step 202 wherein individual and aggregate consumer data, including time-series tradeline data, consumer panel data and internal customer financial data, is obtained from any of the data sources described previously as inputs for consumer behavior models. In certain embodiments, the individual and aggregate consumer data may be provided in a variety of different data formats or structures and consolidated to a single useful format or structure for processing.
[0039] Next, at step 204 , the individual and aggregate consumer data is analyzed to determine consumer spending behavior patterns. One of ordinary skill in the art will readily appreciate that the models may include formulas that mathematically describe the spending behavior of consumers. The particular formulas derived will therefore highly depend on the values resulting from customer data used for derivation, as will be readily appreciated. However, by way of example only and based on the data provided, consumer behavior may be modeled by first dividing consumers into categories that may be based on account balance levels, demographic profiles, household income levels, or any other desired categories. For each of these categories in turn, historical account balance and transaction information for each of the consumers may be tracked over a previous period of time, such as one to two years. Algorithms may then be employed to determine formulaic descriptions of the distribution of aggregate consumer information over the course of that period of time for the population of consumers examined, using any of a variety of known mathematical techniques. These formulas in turn may be used to derive or generate one or more models (step 206 ) for each of the categories of consumers using any of a variety of available trend analysis algorithms. The models may yield the following types of aggregated consumer information for each category: average balances, maximum balances, standard deviation of balances, percentage of balances that change by a threshold amount, and the like.
[0040] Finally, at step 208 , the derived models may be validated and periodically refined using internal customer data and consumer panel data from sources such as COMSCORE. In various embodiments, the model may be validated and refined over time based on additional aggregated and individual consumer data as it is continuously received by an institution computer 202 over the network 200 . Actual customer transaction level information and detailed consumer information panel data may be calculated and used to compare actual consumer spend amounts for individual consumers (defined for each month as the difference between the sum of debits to the account and any balance transfers into the account) and the spend levels estimated for such consumers using the process 200 above. If a large error is demonstrated between actual and estimated amounts, the models and the formulas used may be manually or automatically refined so that the error is reduced. This allows for a flexible model that has the capability to adapt to actual aggregated spending behavior as it fluctuates over time.
[0041] As shown in the diagram 300 of FIG. 3 , a population of consumers for which individual and/or aggregated data has been provided may be divided first into two general categories for analysis, for example, those that are current on their credit accounts (representing 1.72 million consumers in the exemplary data sample size of 1.78 million consumers) and those that are delinquent (representing 0.06 million of such consumers). In one embodiment, delinquent consumers may be discarded from the populations being modeled.
[0042] In further embodiments, the population of current consumers is then subdivided into a plurality of further categories based on the amount of balance information available and the balance activity of such available data. In the example shown in the diagram 300 , the amount of balance information available is represented by string of ‘+’ 0′ and ‘?’ characters. Each character represents one month of available data, with the rightmost character representing the most current months and the leftmost character representing the earliest month for which data is available. In the example provided in FIG. 3 , a string of six characters is provided, representing the six most recent months of data for each category. The ‘+” character represents a month in which a credit account balance of the consumer has increased. The “0” character may represent months where the account balance is zero. The “?” character represents months for which balance data is unavailable. Also provided in the diagram is the number of consumers falling into each category and the percentage of the consumer population they represent in that sample.
[0043] In further embodiments, only certain categories of consumers may be selected for modeling behavior. The selection may be based on those categories that demonstrate increased spend on their credit balances over time. However, it should be readily appreciated that other categories can be used. FIG. 3 shows in bold two categories selected for modeling. These groups show the availability of at least the three most recent months of balance data with balances that increased in each of those months.
[0044] Turning now to FIG. 4 , therein is depicted an exemplary diagram 400 showing sub-categorization of the two categories of FIG. 3 in bold that are selected for modeling. In the embodiment shown, the sub-categories may include: consumers having a most recent credit balance less than $400; consumers having a most recent credit balance between $400 and $1600; consumers having a most recent credit balance between $1600 and $5000; consumers whose most recent credit balance is less than the balance of, for example, three months ago; consumers whose maximum credit balance increase over, for example, the last twelve months divided by the second highest maximum balance increase over the same period is less than 2; and consumers whose maximum credit balance increase over the last twelve months divided by the second highest maximum balance increase is greater than 2. It should be readily appreciated that other subcategories can be used. Each of these sub-categories is defined by their last month balance level. The number of consumers from the sample population (in millions) and the percentage of the population for each category are also shown in FIG. 4 .
[0045] There may be a certain balance threshold established, wherein if a consumer's account balance is too high, their behavior may not be modeled, since such consumers are less likely to have sufficient spending ability. Alternatively, or in addition thereto, consumers having balances above such threshold may be sub-categorized yet again, rather than being completely discarded from the sample. In the example shown in FIG. 4 , the threshold value may be $5000, and only those having particular historical balance activity may be selected, for example those consumers whose present balance is less than their balance three months earlier, or whose maximum balance increase in the examined period meets certain parameters. Other threshold values may also be used and may be dependent on the individual and aggregated consumer data provided.
[0046] As described in the foregoing, the models generated in the process 200 may be derived, validated and refined using tradeline and consumer panel data. An example of tradeline data 500 from EXPERIAN and consumer panel data 502 from COMSCORE are represented in FIG. 5 . Each row of the data 500 , 502 represents the record of one consumer and thousands of such records may be provided at a time. The statement 500 shows the point-in-time balance of consumers accounts for three successive months (Balance 1 , Balance 2 , and Balance 3 ). The data 502 shows each consumer's purchase volume, last payment amount, previous balance amount and current balance. Such information may be obtained, for example, by page scraping the data (in any of a variety of known manners using appropriate application programming interfaces) from an Internet web site or network address at which the data 502 is displayed. Furthermore, the data 500 and 502 may be matched by consumer identity and combined by one of the data providers or another third party independent of the financial institution. Validation of the models using the combined data 500 and 502 may then be performed, and such validation may be independent of consumer identity.
[0047] Turning now to FIG. 6 , therein is depicted an exemplary process 600 for estimating the size of an individual consumer's spending wallet. Upon completion of the modeling of the consumer categories above, the process 600 commences with the selection of individual consumers or prospects to be examined (step 602 ). An appropriate model derived during the process 200 will then be applied to the presently available consumer tradeline information in the following manner to determine, based on the results of application of the derived models, an estimate of a consumer's size of wallet. Each consumer of interest may be selected based on their falling into one of the categories selected for modeling described above, or may be selected using any of a variety of criteria.
[0048] The process 600 continues to step 604 where a further categorization of the consumers takes place. For example, with respect to bank card or credit card customers the categorization may identify whether each consumer of interest is a ‘revolver,’ typically revolving balances among cards and paying off only a portion of the balance on each statement, or whether the consumer is a ‘transactor,’ typically using the card and paying off the full balance of each statement.
[0049] A variety of algorithms may be used to categorize customers as revolvers or transactors. As one example, for a selected consumer, a paydown percentage over a previous period of time may be estimated for each of the consumer's credit accounts. In one embodiment, the paydown percentage is estimated over the previous three-month period of time based on available tradeline data, and may be calculated according to the following formula:
[0000]
Paydown
%
=
(
The
sum
of
the
last
three
months
'
payments
from
the
account
)
/
(
The
sum
of
three
months
'
balances
for
the
account
based
on
tradeline
data
)
.
[0000] The paydown percentage may be set to, for example, 2% for any consumer exhibiting less than a 5% paydown percentage, and may be set to 100% if greater than 80%, as a simplified manner for estimating consumer spending behaviors on either end of the paydown percentage scale.
[0050] Consumers that exhibit less than a 50% paydown during this period may be categorized as revolvers, while consumers exhibiting a 50% paydown or greater may be categorized as transactors.
[0051] As another example of an algorithm for categorizing, the following algorithm may be implemented to identify a consumer as a revolver or a transactor with regard to individual credit cards or other tradelines associated with the consumer:
First, examine a history of the consumer's tradeline balances for a recent given timeframe of interest, such as for six, twelve, or twenty-four months, and quantify any change in balance values between each two consecutive months. For each two consecutive monthly balances, where MONTH 1 is the earlier balance, and MONTH 2 is the subsequent balance: CHANGE=MONTH 2 −MONTH 1 If|CHANGE|<=10% of MONTH 1 , then this is a REVOLVING CHANGE If|CHANGE|>10% of MONTH 1 , then this is a TRANSACTING CHANGE (but if MONTH 1 =0 and MONTH 2 >0, then this is a TRANSACTING CHANGE For a given tradeline, if 75% or more of the changes within the timeframe are REVOLVING CHANGES, then the consumer is considered a revolver with respect to that tradeline. If 75% or more of the changes within the timeframe are TRANSACTING CHANGES, then the consumer is considered a transactor with respect to that tradeline. Otherwise, the consumer may be categorized as ‘undetermined’ for the tradeline.
[0059] Categorizing a consumer of a given tradeline as a revolver or a transactor, by one of these or another method, may be performed to initially determine what, if any, purchasing incentives are to be made available to the consumer, as described later below.
[0060] The process 600 then continues to step 606 , where balance transfers for a previous period of time are identified from the available tradeline data for the consumer. The identification of balance transfers is desirable since, although tradeline data may reflect a higher balance on a credit account over time, such a higher balance may simply be the result of a transfer of a balance into the account, and thus not indicative of a true increase in the consumer's spending. It is difficult to confirm balance transfers based on tradeline data since the information available is not provided on a transaction level basis. In addition, there are typically lags or absences of reporting of such values on tradeline reports.
[0061] Nonetheless, marketplace analysis using confirmed consumer panel and internal customer financial records has revealed reliable ways in which balance transfers into an account may be identified from imperfect individual tradeline data alone. Three exemplary reliable methods or “rules” for identifying balance transfers from credit accounts, each of which is based in part on actual consumer data sampled, are as follows. It should be readily apparent that these formulas in this form are not necessary for all embodiments of the present process and may vary based on the consumer data used to derive them.
[0062] A first rule identifies a balance transfer for a given consumer's credit account as follows. The month having the largest balance increase in the tradeline data, and which satisfies the following conditions, may be identified as a month in which a balance transfer has occurred:
The maximum balance increase is greater than twenty times the second maximum balance increase for the remaining months of available data; The estimated paydown percent calculated at step 306 above is less than 40%; and The largest balance increase is greater than $1000 based on the available data.
[0066] A second rule identifies a balance transfer for a given consumer's credit account in any month where the balance is above twelve times the previous month's balance and the next month's balance differs by no more than 20%.
[0067] A third rule identifies a balance transfer for a given consumer's credit account in any month where:
the current balance is greater than 1.5 times the previous month's balance; the current balance minus the previous month's balance is greater than $4500; and the estimated paydown percentage from step 306 above is less than 30%.
[0071] In estimating consumer spending, any spending for a month in which a balance transfer has been identified from individual tradeline data as described above may be set to zero for purposes of estimating the size of the consumer's spending wallet, reflecting the supposition that no real spending has occurred on that account.
[0072] In addition to the three above-described rules, when tradeline balance history for all or a plurality of a consumer's tradelines is available, identification of a balance transfer event may include identification of both a first tradeline from which a balance was transferred out and a second tradeline into which the balance was transferred.
[0073] According to one such algorithm that examines monthly changes in individual tradeline balances, a balance transfer may be identified for two tradelines (T 1 and T 2 ) that meet the following conditions:
T 1 has a negative balance change (NEG_BAL) and T 2 has a positive balance change (POS_BAL) that occur within three months of one another. |NEG_BAL|>=$500, and |POS_BAL|>=$500 At least one of |NEG_BAL| and |POS_BAL|>=$1000 NEG_BAL occurs before POS_BAL, unless T 2 has just been opened. |NEG_BAL|>=50% of T 1 's previous monthly balance the smaller of POS_BAL and NEG_BAL is greater than or equal to 50% of the larger of POS_BAL and NEG_BAL
[0080] When a balance transfer is identified according to this algorithm, the monthly balances used to calculate customer spend may be adjusted to reflect the identified balance transfer.
[0081] The process 600 then continues to step 608 , where consumer spending on each credit account is estimated over the next, for example, three month period. The estimated spend for each of the three previous months may then be calculated as follows:
[0000]
Estimated
spend
=
(
the
current
balance
-
the
previous
month
'
s
balance
)
+
(
the
previous
month
'
s
balance
*
the
estimated
paydown
%
from
step
604
above
)
.
[0000] The exact form of the formula selected may be based on the category in which the consumer is identified from the model applied, and the formula is then computed iteratively for each of the three months of the first period of consumer spend.
[0082] Next, at step 610 of the process 600 , the estimated spend is then extended over, for example, the previous three quarterly or three-month periods, providing a most-recent year of estimated spend for the consumer.
[0083] Finally, at step 612 , this in turn may be used to generate a plurality of final outputs for each consumer account. These may be provided in an output file that may include a portion or all of the following exemplary information, based on the calculations above and on information available from individual tradeline data: (i) size of previous twelve month spending wallet; (ii) size of spending wallet for each of the last four quarters; (iii) total number of revolving cards, with revolving balance, and average pay down percentage for each; (iv) total number of transacting cards, and transacting balances for each; (v) number of balance transfers and total estimated amount thereof; (vi) maximum revolving balance amounts and associated credit limits; and (vii) maximum transacting balance and associated credit limit.
[0084] After step 612 , the process 600 ends with respect to the examined consumer. It should be readily appreciated that the process 600 may be repeated for any number of current customers or consumer prospects.
[0085] Referring now to FIGS. 7-10 , therein are depicted illustrative diagrams 700 - 1000 of how such estimated spending is calculated in a rolling manner across each previous three month (quarterly) period. In FIG. 7 , there is depicted a first three month period (i.e., the most recent previous quarter) 702 on a timeline 710 . As well, there is depicted a first twelve-month period 704 on a timeline 708 representing the last twenty-one months of point-in-time account balance information available from individual tradeline data for the consumer's account. Each month's balance for the account is designated as “B#.” B 1 -B 12 represent actual account balance information available over the past twelve months for the consumer. B 13 -B 21 represent consumer balances over consecutive, preceding months.
[0086] In accordance with the diagram 700 , spending in each of the three months of the first quarter 702 is calculated based on the balance values B 1 -B 12 , the category of the consumer based on consumer spending models generated in the process 200 , and the formulas used in steps 604 and 606 .
[0087] Turning now to FIG. 8 , there is shown a diagram 800 illustrating the balance information used for estimating spending in a second previous quarter 802 using a second twelve-month period of balance information 804 . Spending in each of these three months of the second previous quarter 802 is based on known balance information B 4 -B 15 .
[0088] Turning now to FIG. 9 , there is shown a diagram 900 illustrating the balance information used for estimating spending in a third successive quarter 902 using a third twelve-month period of balance information 804 . Spending in each of these three months of the third previous quarter 902 is based on known balance information B 7 -B 18 .
[0089] Turning now to FIG. 10 , there is shown a diagram 1000 illustrating the balance information used for estimating spending in a fourth previous quarter 1002 using a fourth twelve-month period of balance information 1004 . Spending in each of these three months of the fourth previous quarter 1002 is based on balance information B 10 -B 21 .
[0090] It should be readily appreciated that as the rolling calculations proceed, the consumer's category may change based on the outputs that result, and, therefore, different formula corresponding to the new category may be applied to the consumer for different periods of time. The rolling manner described above maximizes the known data used for estimating consumer spend in a previous twelve month period.
[0091] Based on the final output generated for the customer, commensurate purchasing incentives may be identified and provided to the consumer, for example, in anticipation of an increase in the consumer's purchasing ability as projected by the output file. In such cases, consumers of good standing, who are categorized as transactors with a projected increase in purchasing ability, may be offered a lower financing rate on purchases made during the period of expected increase in their purchasing ability, or may be offered a discount or rebate for transactions with selected merchants during that time.
[0092] In another example, and in the case where a consumer is a revolver, such consumer with a projected increase in purchasing ability may be offered a lower annual percentage rate on balances maintained on their credit account.
[0093] Other like promotions and enhancements to consumers' experiences are well known and may be used within the processes disclosed herein.
[0094] Various statistics for validating the accuracy of the processes 300 and 600 are provided in FIGS. 11-18 , for which a consumer sample size was analyzed by the process 200 and validated using twenty-four ( 24 ) months of historic actual spend data. The table 1100 of FIG. 11 shows the number of consumers having a balance of $5000 or more for whom the estimated paydown percentage (calculated in step 604 above) matched the actual paydown percentage (as determined from internal transaction data and external consumer panel data).
[0095] The table 1200 of FIG. 12 shows the number of consumers having a balance of $5000 or more who were expected to be transactors or revolvers, and who actually turned out to be transactors and revolvers, based on actual spend data. As can be seen, the number of expected revolvers who turned out to be actual revolvers ( 80539 ) was many times greater than the number of expected revolvers who turned out to be transactors ( 1090 ). Likewise, the number of expected and actual transactors outnumbered by nearly four-to-one the number of expected transactors that turned out to be revolvers.
[0096] The table 1300 of FIG. 13 shows the number of estimated versus actual instances in the consumer sample in which there occurred a balance transfer into an account. For instance, in the period sampled, there were 148,326 instances where no balance transfers were identified in step 606 above, and for which a comparison of actual consumer data showed there were in fact no balances transferred in. This compares to only 9,534 instances where no balance transfers were identified in step 606 , but there were in fact actual balance transfers.
[0097] The table 1400 of FIG. 14 shows the accuracy of estimated spending (in steps 608 - 612 ) versus actual spending for consumers with account balances (at the time this sample testing was performed) greater than $5000. As can be seen, the estimated spending at each spending level most closely matched the same actual spending level in comparison to any other spending level in nearly all instances.
[0098] The table 1500 of FIG. 15 shows the accuracy of estimated spending (in steps 608 - 612 ) versus actual spending for consumers having most recent account balances between $1600 and $5000. As can be readily seen, the estimated spending at each spending level most closely matched the same actual spending level as compared to any other spending level in all instances.
[0099] The table 1600 of FIG. 16 shows the accuracy of estimated spending versus actual spending for all consumers in the sample. As can be readily seen, the estimated spending at each spending level most closely matched the same actual spending level as compared to any other actual spending level in all instances.
[0100] The table 1700 of FIG. 17 shows the rank order of estimated versus actual spending for all consumers in the sample. This table 1700 readily shows that the number of consumers expected to be in the bottom 10% of spending most closely matched the actual number of consumers in that category, by 827,716 to 22,721. The table 1700 further shows that the number of consumers expected to be in the top 10% of spenders most closely matched the number of consumers who were actually in the top 10%, by 71,773 to 22,721.
[0101] The table 1800 of FIG. 18 shows estimated versus actual annual spending for all consumers in the sample over the most recent year of available data. As can be readily seen, the expected number of consumers at each spending level most closely matched the same actual spending level as compared to any other level in all instances.
[0102] Finally, the table 1900 of FIG. 19 shows the rank order of estimated versus actual total annual spending for all the consumers over the most recent year of available data. Again, the number of expected consumers in each rank most closely matched the actual rank as compared to any other rank.
[0103] Prospective customer populations used for modeling and/or later evaluation may be provided from any of a plurality of available marketing groups, or may be culled from credit bureau data, targeted advertising campaigns or the like. Testing and analysis may be continuously performed to identify the optimal placement and required frequency of such sources for using the size of spending wallet calculations. The processes described herein may also be used to develop models for predicting a size of wallet for an individual consumer in the future.
[0104] Institutions adopting the processes disclosed herein may expect to more readily and profitably identify opportunities for prospect and customer offerings, which in turn provides enhanced experiences across all parts of a customer's lifecycle. In the case of a credit provider, accurate identification of spend opportunities allows for rapid provisioning of card member offerings to increase spend that, in turn, results in increased transaction fees, interest charges and the like. The careful selection of customers to receive such offerings reduces the incidence of fraud that may occur in less disciplined card member incentive programs. This, in turn, reduces overall operating expenses for institutions.
[0105] All of the methods and steps described herein may be embodied within, and fully automated by, software modules executed by general-purpose computers. The software modules may be stored on any type of computer readable medium or storage device.
[0106] Although the best methodologies of the disclosure have been particularly described above, it is to be understood that such descriptions have been provided for purposes of illustration only, and that other variations, both in form and in detail, can be made by those skilled in the art without departing from the spirit and scope thereof, which is defined first and foremost by the appended claims. | Time series consumer spending data, point-in-time balance information and consumer panel information provide input to a model for consumer spend behavior on plastic instruments or other financial accounts, from which approximations of spending ability and share of wallet may be reliably identified and utilized to promote additional consumer spending. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 61/577,831, filed Dec. 20, 2011, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Laundry treating appliances, such as clothes washers, may include a perforate rotatable drum or basket positioned within an imperforate tub. The drum may at least partially define a treating chamber in which a laundry load may be received for treatment according to a selected cycle of operation. During at least one phase of the selected cycle, the drum and laundry load may be spun about a rotational axis at a predetermined high speed, sufficient to centrifugally force and hold the laundry load against the perimeter of the treating chamber, causing liquid to be removed from the laundry load. This speed may be referred to as the “satellization” speed.
[0003] Known methodologies may provide an estimate of satellization speed based upon a determination of laundry load inertia or mass, or the employment of an iterative process of drum rotation. However, these methods may be inaccurate, or inefficient. It would be advantageous to efficiently determine the satellization speed accurately for a selected laundry load.
BRIEF DESCRIPTION OF THE INVENTION
[0004] According to an embodiment of the invention, a method of operating a laundry treating appliance is disclosed. The laundry treating appliance may include a rotatable treating chamber for receiving a laundry load for treatment, and a motor for rotating the treating chamber. The method may include accelerating the rotational speed of the treating chamber from a non-satellizing speed to a satellizing speed by increasing the rotational speed of the motor; generating a first torque signal indicative of the motor torque over time for at least a portion of the accelerating; comparing the shape of the first torque signal to the shape of a second torque signal indicative of rotating the treating chamber when the laundry load is satellized within the treating chamber; and determining the laundry load is satellized when the shape of the first torque signal matches the shape of the second torque signal.
[0005] According to another embodiment of the invention, a laundry treating appliance for automatically treating a laundry load according to at least one cycle of operation is disclosed. The laundry treating appliance may include a rotatable treating chamber for receiving the laundry load for treatment; a motor for rotating the treating chamber; a speed sensor outputting a speed signal indicative of the rotational speed of the motor; a torque sensor outputting a torque signal indicative of the torque of the motor; and a controller operably coupled to the motor and receiving the speed signal and torque signal. The controller may provide an acceleration signal to the motor to increase the rotational speed of the motor to accelerate the rotational speed of the treating chamber from a non-satellizing speed to a satellizing speed. The controller may also determine that the treating chamber has reached the satellizing speed by determining when the shape of at least a portion of the torque signal matches a corresponding portion of a reference torque signal, which is indicative of the torque when the laundry load is satellized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] In the drawings:
[0007] FIG. 1 is a vertical sectional view of a laundry treating appliance in accordance with an exemplary embodiment of the invention.
[0008] FIG. 2 is a schematic view of a control system comprising a part of the laundry treating appliance illustrated in FIG. 1 .
[0009] FIGS. 3A-C are schematic views of the rotation of a laundry load in a rotating drum for increasing drum rotation speeds, where the motion of the laundry changes from tumbling ( FIG. 3A ) to satellized ( FIG. 3C ).
[0010] FIGS. 4A-B are graphical representations of a sinusoidal reference torque curve and an actual torque curve for a rotating laundry load at an increasing drum rotation speed.
[0011] FIGS. 5A-C are graphical representations of a reference torque curve and an actual torque curve in raw form, in reference, scaled, and biased form, and in reference, scaled, biased, and shifted form.
[0012] FIGS. 6A-C are graphical representations of a reference torque curve and an actual torque curve in reference, scaled, biased, and shifted form, in reference, scaled, biased, shifted, and frequency adjusted form based upon 100 data samples per cycle, and in reference, scaled, biased, shifted, and frequency adjusted form based upon 200 data samples per cycle.
[0013] FIGS. 7A-B are graphical representations of an array of data points representing actual torque and an array of reference torque data points twice the number of the actual torque data points.
[0014] FIGS. 8A-C are graphical representations of a reference torque curve and an actual torque curve generated during an exemplary 4 th drum revolution ( FIG. 8A ), an exemplary 5 th drum revolution ( FIG. 8B ), and an exemplary 6 th drum revolution ( FIG. 8C ), illustrating a comparison metric that decreases to a value below a threshold value as the reference torque curve and actual torque curve become coincidental.
DETAILED DESCRIPTION
[0015] FIG. 1 is a schematic view of a laundry treating appliance 10 according to an embodiment of the invention. The laundry treating appliance 10 may be any appliance which performs a cycle of operation to clean or otherwise treat items placed therein, non-limiting examples of which include a horizontal or vertical axis clothes washer; a combination washing machine and dryer; a tumbling or stationary refreshing/revitalizing machine; an extractor; a non-aqueous washing apparatus; and a revitalizing machine. Exemplary embodiments of the invention will be described herein in the context of a horizontal axis clothes washing machine.
[0016] The laundry treating appliance 10 is illustrated in FIG. 1 as including a structural support system comprising a cabinet 12 defining a housing within which a laundry holding system may reside. The cabinet 12 may be a housing having a chassis and/or a frame, defining an interior enclosing components typically found in a conventional washing machine, such as motors, pumps, fluid lines, valves, controls, sensors, transducers, and the like. Such components will not be described further herein except as necessary for a complete understanding of the invention.
[0017] The laundry holding system may comprise a tub 14 supported within the cabinet 12 by a suitable suspension system 16 , and a drum 18 provided within the tub 14 defining at least a portion of a laundry treating chamber 20 . The drum 18 may include a plurality of perforations 22 such that liquid may flow between the tub 14 and the drum 18 through the perforations 22 . A plurality of baffles 24 may be disposed on an inner surface of the drum 18 to lift a laundry load 26 received in the treating chamber 20 while the drum 18 rotates. It is also within the scope of the invention for the laundry holding system to comprise only a tub, with the tub defining the laundry treating chamber.
[0018] Other known components may include a door 28 which may be movably mounted to the cabinet 12 to selectively close both the tub 14 and the drum 18 . A bellows 30 may couple an open face of the tub 14 with the cabinet 12 , with the door 28 sealing against the bellows 30 when the door 28 closes the tub 14 .
[0019] The suspension system 16 may include one or more suspension elements, such as springs, dampers, lifters, cushions, bumpers, and the like, for dynamically suspending the laundry holding system within the structural support system.
[0020] The laundry treating appliance 10 may also include a wash aid dispensing system 32 , a liquid distribution system 34 , a liquid recycling/disposal system 36 , and a drum drive system 40 , which will be described further only as necessary for a complete understanding of the invention.
[0021] The drum drive system 40 , for rotating the drum 18 within the tub 14 may include a motor 42 , which may be directly coupled with the drum 18 through a drive shaft 44 to rotate the drum 18 about a rotational axis during a cycle of operation. The motor 42 may be a brushless permanent magnet (BPM) motor. Other motors, such as an induction motor or a permanent split capacitor (PSC) motor, may also be used. The motor 42 may rotate the drum 18 at various speeds in either rotational direction.
[0022] The laundry treating appliance 10 may include a control system 50 for controlling the operation of the laundry treating appliance 10 to implement one or more cycles of operation. The control system 50 may include a controller 52 located within the cabinet 12 and a user interface 54 that is operably coupled with the controller 52 . The user interface 54 may include one or more knobs, dials, switches, displays, touch screens and the like for communicating with the user, such as to receive input and provide output. The user may enter different types of information including, without limitation, cycle selection and cycle parameters, such as cycle options. The controller 52 may control the operation of the laundry treating appliance 10 utilizing a selected motor-control process, such as a closed loop speed control process.
[0023] As illustrated in FIG. 2 , the controller 52 may be provided with a memory 56 and a central processing unit (CPU) 58 . The memory 56 may be used for storing the control software that is executed by the CPU 58 in completing a cycle of operation using the laundry treating appliance 10 and any additional software, plus motor torque signals and reference torque signals. Examples, without limitation, of cycles of operation include: wash, heavy duty wash, delicate wash, quick wash, pre-wash, refresh, rinse only, and timed wash. The memory 56 may also be used to store information, such as a database or table, and to store data received from one or more components of the laundry treating appliance 10 that may be communicably coupled with the controller 52 . The database or table may be used to store the various operating parameters for the one or more cycles of operation, including factory default values for the operating parameters and any adjustments to them by the control system or by user input.
[0024] The controller 52 may be operably coupled with one or more components of the laundry treating appliance 10 for communicating with and controlling the operation of the components to complete a cycle of operation. For example, the controller 52 may be operably coupled with the wash aid dispensing system 32 , the liquid distribution system 34 , the liquid recycling/disposal system 36 , the drum drive system 40 , valves, diverter mechanisms, flow meters, and the like, to control the operation of these and other components to implement one or more of the cycles of operation.
[0025] One or more sensors and/or transducers, which are known in the art, may be provided in one or more of the systems of the laundry treating appliance 10 , and coupled with the controller 52 , which may receive input from the sensors/transducers. Non-limiting examples of sensors that may be communicably coupled with the controller 52 include a treating chamber temperature sensor, a moisture sensor, a load sensor 60 , a wash aid sensor, and a position sensor, which may be used to determine a variety of system and laundry characteristics, such as laundry load inertia or mass. Motor speed and motor torque may be represented by outputs provided by the motor 42 , or may be provided by a motor speed sensor 62 and motor torque sensor.
[0026] A summary of the disclosed method may be described as follows. During a cycle of operation, the drum 18 may be accelerated one or more times to remove liquid from the laundry load 26 . During the acceleration of the drum 18 , the motor torque may be sampled over each drum revolution and compared to one period of a reference sine wave. A metric may be developed that quantifies a variation in a torque sample buffer relative to the reference sine wave signal. The metric may be devised to be a function of the variation, such that a change in the variation, results in a change in the metric. For simplicity, it is contemplated that an increase in the variation will result in an increase in the metric. The speed at which the laundry load 26 becomes completely satellized may be determined by monitoring the metric for each drum revolution, and comparing it to a preselected threshold metric value. Load satellization may be indicated once the metric drops below the threshold value.
[0027] At drum rotational speeds lower than the satellization speed, as illustrated in FIG. 3A , some or all of the laundry load 26 may be tumbling. At this speed, illustrated in FIG. 4A , the motor torque signal 66 may have high-frequency components 68 , 70 , 72 , 74 effectively superimposed on a generally sinusoidal reference drum frequency signal 76 , which may be the result of portions of the laundry load following a trajectory inside the drum 18 that is shorter than one full drum revolution ( FIG. 3A ). As the rotational speed increases, and a larger percentage of the load is forced against the interior of the drum 18 ( FIG. 3B ), the torque signal 66 may trend toward a sinusoid, e.g. between the 4th and 6th time interval or drum revolution of FIG. 4A , having a frequency approaching the drum frequency 76 , and may have fewer high-frequency components. As the drum speed reaches, and then exceeds, the satellization speed ( FIG. 3C ), the torque signal 66 may develop into a sine wave having a frequency matching the drum rotational frequency, the magnitude of which may be proportional to the degree of off-balance of the laundry load in the drum 18 .
[0028] This behavior of the torque signal 66 may be attributed to the orientation of a horizontal axis drum 18 , and an interaction between a laundry load 26 and a closed loop speed controller. When the drum 18 is stationary, a wet load may rest on the bottom of the drum 18 . A typical speed profile, illustrated in FIG. 4B , utilized to distribute laundry items about the interior of the drum 18 may be a ramp 80 accelerating at a fixed rate from about 40 RPM to about 100 RPM. As the speed increases, the combination of friction and baffles 24 along the interior perimeter of the drum 18 may catch some of the laundry load 26 and lift it up along the side of the drum 18 until portions of the load separate from the drum 18 and drop back to the bottom.
[0029] A mass of laundry along the interior perimeter of the drum wall may change the balance of the drum 18 , which may cause a somewhat reduced drum speed. In order to track a selected speed profile target as closely as possible, the speed controller may increase the motor torque. When a laundry load portion separates from the drum wall, the speed may increase slightly, leading the controller 52 to call for a reduced torque to appropriately regulate the speed. This repeated variation in torque and/or speed may cause a relatively high-frequency torque ripple that may be observed at rotational speeds less than the satellization speed.
[0030] As the selected speed profile continues, the drum 18 accelerates, and through the combined effect of the baffles 24 and drum wall friction, the laundry load may accelerate as well. The uncontrolled process of laundry load portions adhering to and separating from the interior of the drum 18 may continue until the laundry load has achieved a high enough rotational speed that centrifugal force overcomes the force of gravity at the top of the drum 18 , and the load remains distributed along the drum wall through a complete revolution of the drum 18 . Centrifugal force (CF) is a function of a mass (m) of an object, e.g. a laundry item, an angular velocity (w) of the object, and a distance, or radius (r) at which the object is located with respect to an axis of rotation (X), or a drum axis. Specifically, the equation for the centrifugal force (CF) acting on a laundry item within the drum 18 is:
[0000] CF= m*ω 2 *r
[0031] The centrifugal force (CF) acting on any single item in the laundry load may be modeled by the distance the center of gravity of that item is from the axis of rotation (X) of the drum 18 . Thus, when the laundry items are stacked upon each other, which is often the case, those items having a center of gravity closer to the axis of rotation (X) experience a smaller magnitude centrifugal force (CF) than those items having a center of gravity farther away. It is possible to control the speed of rotation of the drum 18 such that the closer items will experience a centrifugal force (CF) less than 1 G, permitting them to tumble, while the farther away items still experience a centrifugal force (CF) equal to or greater than 1 G, retaining them in a fixed position relative to the drum 18 .
[0032] Momentum may also urge the laundry load to travel a complete revolution across the top of the drum 18 at slightly lower speeds than the satellization speed. While some portions of the load may remain against the drum wall, the radius of rotation for other, tumbling portions may decrease. Thus, the tumbling portions must be rotated at a higher higher speed to overcome gravity. For example, if a 4-inch thick layer of laundry load is distributed about the inside perimeter of the drum 18 , the speed required to satellize any tumbling items may be approximately 15 RPMs higher than if the drum 18 were empty.
[0033] The following equation may define the torque, T, for a fully satellized laundry load:
[0000] T=J{dot over (ω)}+Cω+D+A cos(θ DRUM )+ B sin(θ DRUM ),
[0000] where
T: Torque, J: Inertia, C: Viscous damping coefficient, D: Coulomb friction torque, ½√{square root over (A 2 +B 2 )}: Unbalance torque amplitude, and θDRUM: Drum position.
[0040] For a fixed speed, viscous damping coefficient, and coulomb friction coefficient, the torque equation may simplify to the following:
[0000] T=K 1 +A cos(θ DRUM )+ B sin(θ DRUM ),
[0000] where
K 1 =Cω+D, {dot over (ω)}=0, T=K 1 +√{square root over (A 2 +B 2 )}*sin(θ DRUM +π/4), T=K 1 +K 2 sin(θ DRUM +φ), and K 2 =√{square root over (A 2 +B 2 )}.
[0046] The position of the drum may be a function of time:
[0000] θ DRUM =ω*t.
[0047] Therefore, the torque may be a function of time:
[0000] T ( t )= K 1 +K 2 sin(ω* t +φ).
[0048] As may be recognized, the torque may be a sinusoid with a DC offset K 1 , amplitude K 2 , and frequency ω, which is equal to the drum frequency in radians per second.
[0049] For a constant acceleration, the torque equation may include an additional speed dependency as follows:
[0000] T=J{dot over (ω)}+Cω+D+K 2 sin(θ DRUM +φ), and
[0000] T=Cω+K 1 +K 2 sin(θ DRUM +φ),
[0000] where
[0000]
K
1
=J{dot over (ω)}+D.
[0050] In the case of constant acceleration, the drum speed and drum position are functions of time as follows:
[0000] ω( t )= t *RR+ω(0),
[0000] where
RR=ramp rate (rad/sec), ω(0)=speed at t=0, θ DRUM (t)=∫ o t ω(τ)dτ, θ DRUM (t)=∫ o t (τ*RR+ω(0))dτ,
[0000]
θ
DRUM
(
t
)
=
1
2
t
2
*
RR
+
ω
(
0
)
*
t
,
and
T
(
t
)
=
C
(
t
*
RR
+
ω
(
0
)
)
+
K
1
+
K
2
sin
(
1
2
t
2
*
RR
+
ω
(
0
)
*
t
+
ϕ
)
.
[0055] The objective of the algorithm is to detect the speed at which a particular laundry load may become satellized while the drum is accelerating at a constant ramp rate. The fact that the torque signal becomes a sinusoid with a single frequency matching the drum speed at or above satellization speed may be the basis for the algorithm. The algorithm may be based upon determining how much the torque signal differs from one period of a sinusoid for each drum revolution.
[0056] The torque signal may be sampled with a fixed sampling rate and stored in a buffer memory. The length of the buffer memory may be sufficient to hold enough sampling data for one complete drum revolution at a lowest speed of interest. For example, the fixed sampling rate may be 100 Hz, and the lowest drum speed of interest may be 45 RPM. One drum revolution at 45 RPM may take 1.33333 seconds, so sampling every 0.01 second may require 134 samples. Thus, the maximum buffer length required may be 134.
[0057] The algorithm may be intended to be implemented in embedded code. Moreover, because the sine function may be unavailable to recall during data sampling, one period of a normalized sine wave may be generated from a fixed number of samples, and stored in memory ahead of time. More sampling data may enable higher resolution, but at the expense of more memory. This array of a fixed number of samples from a normalized sine wave may be referred to as a “reference signal,” and may be expressed as follows:
[0000]
Ref
(
n
)
=
sin
(
2
π
*
n
L
)
,
[0000] where
nε{0, 1, 2, 3, . . . L−1} and L=length of reference array.
[0060] The length of the reference array may be at least twice the length of the torque buffer array to assure sufficiently high resolution when selecting the samples from the reference array to compare to each sample in the torque array.
[0061] The torque signal from the equation for T(t), above, may be in continuous time, and the process of sampling with a fixed sampling period, T s , may have the following effect on the equation:
[0000] t=k*T s ,
[0000] where
[0000] k ε{0,1,2,3 , . . . L− 1}, and
[0000]
T
(
kT
s
)
=
C
(
kT
s
*
RR
+
ω
(
0
)
)
+
K
1
+
K
2
sin
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
+
ϕ
)
.
[0062] For low speeds, the viscous damping coefficient may be very small, and over one period of the sine wave, (kT s *RR) may be a small number, so that the expression C(kT s *RR+ω(0)) may be simplified to (C*ω(0)). This term may be grouped with K 1 so that the equation may simplify to the following:
[0000] T ( kT s )=δ+ K 2 sin(( kT s *RR +ω(0))* kT s +φ),
[0000] where
[0000] δ= C* ω(0)+ K 1 .
[0063] In order to compare the torque signal to the reference signal there are 3 characteristics of the sampled torque signal that are useful to determine: a constant offset (δ), an amplitude (K 2 ), and a phase (φ). If these 3 parameters are determined, the reference signal may be scaled by K 2 , biased by δ, and shifted by φ. In the following example, δ=1, K 2 =4, and φ=π/4.
[0064] FIG. 5A illustrates a raw reference signal 82 and a torque signal 84 . FIG. 5B illustrates a scaled and biased reference signal 86 and a torque signal 88 . FIG. 5C illustrates a scaled, biased, and shifted reference signal 90 and a torque signal 92 .
[0065] FIG. 5C illustrates the torque signal 92 initially matching the reference signal 90 well, but as time progresses, the torque signal 92 may lead the reference signal 90 . This is the result of the torque sine wave frequency increasing at a constant rate as the drum speed increases at a constant rate. In this example, the ramp rate is 5 RPM per second (0.0833 Hz/s), and at the end of the cycle, the torque signal frequency is about 8% higher than the reference signal.
[0066] To account for an increasing frequency of the torque signal, the sampling data from the reference array may be selected at an increasing time interval. To determine the correct relationship, the expressions for the torque and reference array may be equated, and solved for the reference array sample, n. (For the derivation, the phase, φ, may be set to 0, and the ramp rate, RR, and initial speed, ω(0), may be converted to Hz/s and Hz, respectively.) Thus:
[0000]
[
Ref
(
n
)
=
δ
+
K
2
sin
(
2
π
*
n
L
)
]
=
[
T
(
kT
s
)
=
δ
+
K
2
sin
(
2
π
*
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
)
)
]
,
[
δ
+
K
2
sin
(
2
π
*
n
L
)
]
=
[
δ
+
K
2
sin
(
2
π
*
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
)
)
]
,
(
n
L
)
=
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
)
,
and
n
=
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
)
*
L
.
[0067] Finally, by implementing the above equation for n and select sampling data from the reference array, we may observe how the torque and reference signals line up. FIG. 6A illustrates the sampled torque signal 92 and the scaled, biased, and shifted reference signal 90 shown in FIG. 5C . FIG. 6B illustrates the sampled torque signal 96 and the scaled, biased, shifted, and frequency-adjusted reference signal 94 with a 100 point reference sampling array. FIG. 6C illustrates the same signal correlation as illustrated in FIG. 6B , but with a 200 point reference sampling array. The effect of utilizing more samples in the reference array may be observed from FIGS. 6B and 6C .
[0068] The above equation for n may enable a comparison of the torque signal to the reference signal for any combination of starting speeds and ramp rates. For example, if the ramp rate were 0, and the starting speed were 60 RPM (1 Hz):
[0000]
n
=
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
)
*
L
,
n
=
(
1
*
kT
s
)
*
L
[0069] If the reference array length were 400, and the sampling period, T s were 0.01, then:
[0000]
n
=
k
(
1
100
)
*
400
,
n
=
4
k
[0070] An actual comparison may be accomplished by iterating through the entire torque array buffer, and comparing each sample to the appropriate sample from the reference array using the equation:
[0000]
n
=
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
)
*
L
.
[0000] to determine the reference sample size. For example, with a torque sampling period=0.1 second, and a length of the reference array=20, then n=2k. This is illustrated in FIGS. 7A and 7B , wherein values of k and n, respectively, may be correlated. FIG. 7A illustrates that every data point 104 on the torque array 102 may be utilized. FIG. 7B illustrates that every other element 108 from the reference array 106 may be ignored.
[0071] As a loop through the array from k=0 to k=N−1 progresses, a magnitude of the difference between the two points, i.e. torque array data point 104 and reference array element 108 , may be calculated:
[0000]
(
T
(
k
)
-
Ref
(
n
)
)
2
2
,
where
k
∈
{
0
,
1
,
2
,
3
,
…
N
-
1
}
,
n
=
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
)
*
L
,
Metric
=
∑
k
=
0
N
-
1
(
T
(
k
)
-
Ref
(
n
)
)
2
2
,
and
n
=
(
1
2
(
kT
s
)
2
*
RR
+
ω
(
0
)
*
kT
s
)
*
L
.
[0072] The magnitude of the difference at each point may be summed for the entire array, then divided by the length of the torque buffer array. As an example, assuming each point in the array differs by 1, and the length of the torque array is 100, then Metric=1.
[0073] FIGS. 8A , 8 B, and 8 C illustrate additional analyses of the drum revolutions 4 , 5 , and 6 , respectively, illustrated in FIG. 4A . The shaded area 110 , 112 , 114 in each figure may essentially represent the metric. In FIG. 8A , for example, the shaded area 110 , i.e. the degree to which the torque curve 72 deviates from the reference curve 76 , is also represented by a bar graph 116 . An empirical threshold value 122 established for a selected laundry treating appliance running a selected cycle of operation for a selected laundry load is also represented with the bar graph 116 .
[0074] As the laundry load becomes satellized, the area 110 , 112 , 114 between the curves may be reduced, and the associated metric 116 , 118 , 120 may reflect this reduction, as illustrated in FIGS. 8A , 8 B, and 8 C. When the metric 120 , i.e. the difference between the torque curve and the reference curve, decreases to a value less than the empirical threshold value 122 , as illustrated in FIG. 8C , the laundry load may be said to be satellized. For example, in FIG. 8C , after completing revolution 6 , the metric 120 is less than the threshold value 122 , and the laundry load is therefore satellized. FIG. 8C indicates a satellization speed of approximately 60 RPM.
[0075] Selected equal-length intervals, or “windows,” of time may be established, and a torque signal may be generated for each selected interval. Data associated with each interval may be collected and evaluated. The intervals may advance forward in time as acceleration proceeds and satellization develops. The metric, or difference between the torque signal and the reference torque signal, may be determined as a difference in the amplitudes of the torque and reference torque signals. Alternatively, the difference between the signals may be the difference between a running average of the amplitudes of the torque signal and the reference signal. The running average may be a moving running average, which may be determined from a window of data points of fixed length advancing in time.
[0076] The embodiment of the invention described herein provides a method for readily determining a satellization speed for a selected laundry treating appliance running a selected cycle of operation for a selected laundry load. Thus, the satellization speed can be efficiently reached for effective liquid extraction while minimizing vibration and energy usage.
[0077] While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention which is defined in the appended claims. | A laundry treating appliance may include a rotatable treating chamber for receiving a laundry load for treatment, and a motor for rotating the treating chamber, and may be operated such that during the acceleration of the laundry load toward a satellizing speed, the satellizing of the laundry load may be detected, whereby subsequent operation of the laundry treating appliance may be controlled based on the detection. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cooling device for a notebook personal computer for cooling an exothermic member such as an electronic element in a personal computer by using a heat pipe for transferring the heat as the latent heat of a working fluid.
2. Related Art
In recent years, there are remarkably widespread the so-called "portable personal computers" of notebook or sub-notebook type. In accordance with the increase in the number of functions or the improvement in the processing speed, on the other hand, the output of an electronic element such as a processing unit is rising year by year. It is, therefore, desired to improve the capacity of a cooling device for cooling the exothermic element. In the prior art, for example, there has been a cooling device which adopts a heat pipe excellent in the heat transfer ability. In the cooling device of this kind, more specifically, the heat pipe has one end portion arranged on the electronic element such as the processing unit acting as a heat source and its other end portion arranged in a heat transferable manner on an aluminum sheet, as arranged in the display for shielding the noise.
When the electronic element generates the heat as the use of the personal computer proceeds, a working fluid in a liquid phase, as confined in the container of the heat pipe, is heated and evaporated. The vapor of the working fluid flows to the other end portion under a lower internal pressure of the container, i.e., to the end portion arranged on the aluminum sheet so that it is derived of the heat and is condensed. This heat is released from the aluminum sheet to the internal space of the display and is dissipated by the natural convection from the inside of the display to the outside. The working fluid having restored the liquid phase is circulated by the gravity or the capillary pressure of a wick toward the end portion, as arranged on the electronic element, of the container until it is heated and evaporated again. As a result, the electronic element is cooled and prevented from being overheated.
Here, the notebook personal computer is earnestly desired to have a small size and a low weight because its major purpose is the portability. This severely restricts the space for the heat pipe to occupy in the internal space of the personal computer case. Usually, the display, as equipped with the aluminum sheet, is so hinged to the personal computer case as can be freely opened/closed (or erected/inclined). When the display is to be employed as the heat dissipating means, the heat transfer means such as the heat pipe has to be so constructed as can be freely bent at the connected portion between the personal computer case and the display. The heat pipe per se is excellent in the heat transfer ability but is required to have a high gas tightness for keeping its characteristics, and it is difficult to manufacture a freely bendable heat pipe.
SUMMARY OF THE INVENTION
A main object of the present invention is to provide a cooling device for a notebook personal structure capable of exemplifying the heat dissipating means by a display attached in an openable/closable manner to a personal computer case and enhancing the cooling characteristics by using a heat pipe.
Therefore, the present invention is applied to a notebook personal computer in which a display is attached in an openable/closable manner through a hinge mechanism to the personal computer body accommodating an exothermic electronic element. The structure of the invention comprises: a first heat pipe having one end portion arranged along the display; and a second heat pipe having one end portion arranged in a heat transferable manner on the electronic element. The other end portion of one heat pipe is arranged on the center axis of rotation in the hinge mechanism and is held relatively rotatably by a connector. This connector further holds the other end portion of the other heat pipe such that the heat can be transferred with the end portion of the one heat pipe. The connector is fixed on the personal computer body or display in which the other heat pipe is arranged.
When the electronic element generates heat as the personal computer body is used, this heat is transferred to the one end portion of the second heat pipe of the cooling device of the invention. Then, this heat evaporates the liquid-phase working fluid which is confined in the container of the second heat pipe. The vapor of the working fluid flows to the other end portion having the lower temperature and internal pressure of the container, i.e., to the end portion held by the connector, so that it is derived of its heat and condensed by the first heat pipe and the connector.
Since the end portion, as held by the connector, of the second heat pipe is covered integrally with the one end portion of the first heat pipe, the heat of the electronic element is transferred from the second heat pipe to the first heat pipe.
In this case, because of a large area for the heat transfer between the end portions of the individual heat pipes, the heat is efficiently transferred between the heat pipes. Here, the working fluid, as having been derived of the heat to restore the liquid phase, of the second heat pipe is circulated by the gravity or the wick to the end portion, as located at the side of the electronic element, of the container.
On the other hand, the liquid-phase working fluid of the first heat pipe is evaporated by the heat which is transmitted through the second heat pipe and the connector. The vapor of the working fluid flows toward the end portion, as arranged in the display, of the container so that it is derived of the heat by the display and condensed. In short, the heat of the electronic element is transferred through the connector to the first heat pipe. As a result, the electronic element is cooled. Moreover, the end portion, as held by the connector of the rotatably held heat pipe held is arranged on the same axis as the center axis of the hinge mechanism, so that the display can be turned (or opened/inclined) without any difficulty.
In the present invention, on the other hand, one heat pipe has an end portion held relatively rotatably by the connector, and this connector is fixed on the member in which the other heat pipe is arranged, so that these heat pipes and the connector can construct the hinge for the display.
The above and further objects and novel features of the present invention will more fully appear from the following detailed description when the same is read with reference to the accompanying drawings. It is to be expressly understood, however, that the drawings are for purposes of illustration only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a notebook personal computer according to the present invention;
FIG. 2 is a schematic view showing an arrangement of a connector with respect to a display and a personal computer body;
FIG. 3 is a partially cut-away schematic view showing the connector;
FIG. 4 is a sectional view taken along line IV--IV of FIG. 3;
FIG. 5 is a sectional view showing an arranging relation among individual heat pipes, a thermal joint and the connector;
FIG. 6 is a sectional view showing the state in which the first heat pipe is arranged in an electromagnetic shielding plate;
FIG. 7 is a perspective view showing the state in which the first heat pipe is arranged in the arranging portion of the display;
FIG. 8 is a schematic view showing an arranging relation between a cavity and an outlet;
FIG. 9 is a schematic view showing an arranging relation between the cavity and an inlet in the display;
FIG. 10 is a schematic view showing the cavity and the first heat pipe;
FIG. 11 is a sectional view showing a heat sink and the first heat pipe;
FIG. 12 is a partially cut-away schematic view showing a second heat pipe having a recess;
FIG. 13 is a sectional view taken along line XIII--XIII of FIG. 12;
FIG. 14 is a schematic view showing a connector having a cover;
FIG. 15 is a sectional view taken along line XV--XV of FIG. 14;
FIG. 16 is a schematic view showing a connector having bolts and nuts;
FIG. 17 is a sectional view taken along line XVII--XVII of FIG. 16;
FIG. 18 is a schematic view showing a cover having an O-ring;
FIG. 19 is a sectional view taken along line XIX--XIX of FIG. 18; and
FIG. 20 is a perspective view showing a notebook personal computer having a hinge constructed of the first heat pipe and the connector.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be specifically described with reference to FIGS. 1 to 4. In FIG. 1, a personal computer body 1 is a rectangular container made of a plastic panel or a metal panel of a magnesium alloy or the like and is given a size of A5 to A4 according to the JIS (Japanese Industrial Standards). On the bottom of the personal computer body 1, there is mounted a CPU (Central Processing Unit) 2 corresponding to the electronic element of the invention. A heat transfer plate 3 made of aluminum is placed on the upper face of the CPU 2.
A keyboard 4 is fitted in the upper face of the personal computer body 1. On an edge of the personal computer body 1, there are opposed two support blocks 5 which are protruded upward. Hinge pines 6 are individually rotatably supported at their one-end portions by the support blocks 5. Here, these two hinge pins 6 are so arranged that their leading ends confront each other.
The personal computer body 1 is equipped with a display 7 at its upper face. Specifically, the display 7 is formed into such a planar shape as is equipped on its one side with an image display screen 11 made of a planar liquid crystal panel. The display 7 is equipped therein with a metal sheet, as exemplified by an electromagnetic shielding sheet 14.
The display 7 is equipped, at its lower edge, as seen in FIG. 1, that is, at positions adjacent to the individual support blocks 5 of the personal computer body 1, with support blocks 8 which are protruded downward. These two support blocks 8 individually support the other end portions of the hinge pins 6 rotatably. In short, the hinge pins 6 and the four support blocks 5 and 8 constitute together a hinge 9 corresponding to the a hinge mechanism of the present invention. As a result, the display 7 is so attached to the personal computer body 1 that it can be freely opened/closed on the hinge 9 within a range of about 130 degrees.
To the personal computer body 1, as located between the support blocks 8 of the display 7, there is attached by suitable means a connector 10. This connector 10 is made of a metal block of copper or aluminum. In this connector 10, there are formed two circular holes 12 of the same size, which are extended in parallel with the axis of the hinge pins 6. These two holes 12 are vertically arranged in parallel such that the upper hole 12 has a center axis aligned with that of the hinge pins 6 and such that the individual holes 12 communicate with each other. Moreover, these holes 12 are individually made straight and extended through the connector 10 to the left and right side faces, as seen in FIG. 3.
Into the upper hole 12, there is inserted from the right side of FIG. 3 one end portion of a first heat pipe 13. This first heat pipe 13 is prepared by confining pure water as a working fluid 16 in a copper container having a circular section and plated with hard chromium, and the external diameter of this container is set to substantially the same size of the internal diameter of the hole 12. As a result, the first heat pipe 13 is so held in the connector 10 as can rotate on its center axis. Moreover, one end portion, as arranged in the hole 12, of the first heat pipe 13 is arranged on the same axis as that of the hinge pins 6.
The other end of the first heat pipe 13 is suitably folded and inserted into the display 7 and is mounted on the electromagnetic shielding sheet 14 along the right side edge thereof, as seen in FIG. 2, by the not-shown suitable means. This electromagnetic shielding sheet 14 is arranged, as shown in FIG. 6, on the back of the display screen 11 inside of the display 7.
Into the lower hole 12 of the connector 10, there is inserted from the left side of FIG. 3 one end portion of a second heat pipe 15. The other end portion of this second heat pipe 15 is so arranged in the personal computer body 1 as is folded at several portions to along the upper face of the heat transfer plate 3. Moreover, the heat transfer plate 3 and the second heat pipe 15 are fixed on each other by the not-shown suitable means. As a result, the CPU 2 and the second heat pipe 15 are so connected that they can transfer the heat. This second heat pipe 15 is prepared by confining pure water in a copper container having a circular section and plated with hard chromium.
A pasty thermal joint 38 is applied between the individual heat pipes 13 and 15 and the holes 12. When the display 7 is brought up/down, it is turned on the center axis of the first heat pipe 13 while the first heat pipe 13 contacting with the side face of the second heat pipe 15. In other words, the first heat pipe 13 and the second heat pipe 15 are held in close contact independently of the position of the display 7.
Here will be described the operations of the cooling device for the notebook personal computer thus constructed. As the personal computer is used, the heat is generated from the CPU 2 and is transferred through the heat transfer plate 3 to one end portion of the second heat pipe 15. At this instant, a temperature difference is caused between the two end portions of the second heat pipe 15 so that the heat pipe action is automatically started. Specifically, the working fluid 16 in its liquid phase, as confined in the container of the second heat pipe 15, is evaporated by the heat of the CPU 2. When the personal computer is used, the display 7 takes an erected position with respect to the personal computer body 1.
The vapor, as generated by the heat, of the working fluid 16 flows toward the end portion, as held by the connector 10, of the container of the second heat pipe 15 until its heat is absorbed by the container of the first heat pipe 13 so that it is condensed. In short, the heat is transferred from the second heat pipe 15 to the first heat pipe 13. In this case, the heat transfer from the second heat pipe 15 to the first heat pipe 13 is efficient because the first heat pipe 13 for receiving the heat is arranged over the second heat pipe 15 for releasing the heat and because the contacting portion between the first heat pipe 13 and the second heat pipe 15 is covered with the connector 10.
On the other hand, the working fluid 16, as having released the heat to restore the liquid phase, of the second heat pipe 15 is circulated to the end portion, as arranged at the side of the CPU 2, of the container by either the gravity of the capillary pressure to be established by the wick. The working fluid 16 is evaporated again by the heat of the CPU 2, as transferred through the heat transfer plate 3.
The first heat pipe 13 starts its actuation automatically when the heat is transferred thereto from the second heat pipe 15. The display 7 is erected, as described hereinbefore, so that the electromagnetic shielding sheet 14 is naturally placed in the upright position. As a result, the action mode of the first heat pipe 13 is in the bottom heat mode in which the evaporation portion is positioned below the condensation portion. More specifically, the working fluid 16 is evaporated in the inner faces of the end portion, as held by the connector 10, of the container. The vapor of the working fluid 16 flows toward the end portion, as arranged in the display 7, of the container. Then, the vapor of the working fluid 16 has its heat absorbed by the electromagnetic shielding sheet 14 so that it is condensed. In other words, the heat is transferred from the first heat pipe 13 to the electromagnetic shielding sheet 14. This heat is dissipated from the surface of the electromagnetic shielding sheet 14. The working fluid 16, as having restored the liquid phase as a result of the heat release, of the first heat pipe 13 flows down along the inner wall faces of the container. The liquid of the working fluid 16 is evaporated in the portion, as arranged in the circular hole 12 of the connector 10, of the inner face of the container by the heat of the CPU 2, as transferred through the connector 10 and the second heat pipe 15. From now on, the heat transfer cycle by the working fluid 16 like the aforementioned one is continued. As a result, the CPU is cooled so that its overheat is prevented in advance.
Moreover, the first heat pipe 13, as rotatably held by the connector 10, is arranged on the same axis as that of the hinge pins 6 so that the heat transfer between the first heat pipe 13 and the second heat pipe 15 is efficiently effected. As a result, an excellent cooling capacity can be attained no matter whether the display 7 might take an erected or inclined position.
Here will be described another embodiment in which the condensation portion of the first heat pipe 13 is exposed from the display 7. As shown in FIG. 7, the display 7 is provided at its portion along the edge portion of the image display screen 11 with an arranging portion 18. This arranging portion 18 is formed by recessing the outer face of the display 7 linearly. One end portion of the first heat pipe 13 is arranged along the arranging portion 18, and the first heat pipe 13 is fixed on the display 7 by the not-shown suitable means.
According to the cooling device thus constructed, therefore, the heat to be taken from the first heat pipe 13 is mostly dissipated unchangedly to the atmosphere. The remaining heat is transferred to the outer wall face of the display 7 until it is dissipated into the atmosphere. Since the first heat pipe 13 is exposed to the outside of the display 7 and since the display 7 acts as a dissipating face, the heat is not confined in the display 7 so that the capacity for cooling the CPU 2 is improved better than the structure of FIG. 2.
Here will be described another embodiment in which the condensation of the first heat pipe 13 is arranged in the cavity of the display 7. In the right end of the display 7, as shown in FIGS. 8 to 11, there is formed a straight cavity 19 which is directed vertically. This straight cavity 19 has a rectangular opening, for example. In the upper edge portion of the display 7, as located in FIG. 8 immediately above the cavity 19, there is formed an outlet 20 which has the same opening shape as that of the cavity 19. This outlet 20 corresponds to air discharging opening and has communication with the cavity 19.
In the lower edge portion of the display 7 immediately under the cavity 19, on the other hand, there is formed an inlet 21 which has the same opening shape as that of the cavity 19. This inlet 21 corresponds to an air introducing opening and has communication with the cavity 19. In short, the cavity 19 is constructed to extend in the vertical direction of the display 7.
In the cavity 19, there is arranged the first heat pipe 13 which is equipped at its one end portion with a heat sink 22. The end portion, as arranged in the cavity 19, of the first heat pipe 13 is crushed into a planar shape. The heat sink 22 is constructed, for example, by raising a plurality of planar fins 24 from a planar base 23. The heat sink 22 is attached in such a position to the first heat pipe 13 that the individual fins 24 are oriented in the longitudinal direction of the cavity 19. Here, the heat sink 22 and the first heat pipe 13 are integrally fixed by fitting the container of the first heat pipe 13 in a fitting groove 25 which is formed in the back of the base 23.
According to the cooling device thus constructed, therefore, the heat of the CPU 2 is carried by the working fluid 16 of the first heat pipe 13 so that it is transferred to the heat sink 22. The heat thus transferred is dissipated from the surfaces of the base 23 and the individual fins 24 into the cavity 19. The resultant hot air flows upward due to its lower specific gravity and then from the outlet 20 to the outside of the display 7. As a result of this updraft of the air in the cavity 19, the lower portion of the cavity 19 is evacuated to a lower pressure so that cavity 19 is supplied by the air outside of the display 7 by way of the inlet 21.
The air ascends along the cavity 19 and flows out, while contacting with the condensation portion and the heat sink 22 of the first heat pipe 13, from the outlet 20 to the outside of the display 7. In short, a circulating flow is established upward in the cavity 19 so that the CPU 2 is cooled. Then, the working fluid 16 having released the heat to restore the liquid phase flows down along the inner wall face of the container of the first heat pipe 13. Then, the working fluid is evaporated again by the heat of the CPU 2 on the inner face of the portion, as inserted in the hole 12 of the connector 10, of the first heat pipe 13.
As described above, the air flows upward in the cavity 19 so that the heat of the CPU, as transferred from the first heat pipe 13, can be quickly carried to the out side of the display 7. As a result, the capacity for cooling the CPU is improved.
Here will be described another shape of the second heat pipe 15. In connector 10, as shown in FIGS. 12 and 13, there is formed an arranging hole 26 in which two circular holes of a size are vertically juxtaposed in communication. In other words, the arranging hole 26 having a section of numeral 8 is extended to the two side faces in the connector 10. Here, this arranging hole 26 is made straight.
In the upper space of the arranging hole 26, there is inserted one end portion of the first heat pipe 13 from the right side of FIG. 12. On the other hand, the second heat pipe 15 is inserted into the lower space of the arranging hole 26 from the left side of FIG. 12. The second heat pipe 15 is fixed in the connector 10 by adhesion means, for example. Here, the leading end portions of the first heat pipe 13 and the second heat pipe 15 are so arranged inside of the edges of the arranging hole 26 as may not project from the connector 10.
In the upper face of the portion, as fitted in the connector 10, of the second heat pipe 15, there is formed a recess 27 which is extended in the axial direction of the container. This recess 27 is formed into such a curved arcuate shape as to match the sectional shape of the container of the first heat pipe 13. In other words, the radius of curvature of the recess 27 is set to a value substantially equal to that of the lower portion of the first heat pipe 13.
Thus, the lower portion of the container of the first heat pipe 13 is fitted along the recess 27 in the arranging hole 26 of the connector 10. Moreover, the first heat pipe 13 is not fixed with respect to the second heat pipe 15 and the arranging hole 26. Therefore, the first heat pipe 13 and the connector 10 can freely turn on the center axis of the first heat pipe 13. As a result, the connector 10 is constructed to turn on the center axis with the first heat pipe 13 closely contacting with the recess 27, as the display 7 is erected/inclined. In other words, the recess 27 and the first heat pipe 13 are held in close contact no matter what position the display 7 might take.
As a result, the connected portion between the first heat pipe 13 and the second heat pipe 15 is not a linear contact but a facial contact so that the heat resistance between the first heat pipe 13 and the second heat pipe 15 is low. Moreover, the first heat pipe 13 or a member for receiving the heat is arranged over the second heat pipe 15 or a member for releasing the heat so that the heat transfer is excellent at the connected portion between the first heat pipe 13 and the second heat pipe 15.
Here will be described another example of the connector 10. As shown in FIGS. 14 and 15, the portion of the surface of the connector 10 excepting the hole 12 is sheathed with a cover 28 which is made of plastics having a higher heat insulation than that of the metal making the connector 10. Specifically, this cover 28 also has a circular hole of the same size as that of the hole 12 of the connector 10 so that it may not check the turning action of the first heat pipe 13.
According to the construction described above, therefore, the connector 10 is sheathed with and thermally insulated by the cover 28 so that the heat transfer between the first heat pipe 13 and the second heat pipe 15 is more efficient than the connector 10 having the construction shown in FIGS. 3 and 4.
Here will be described still another example of the connector 10. As shown in FIGS. 16 and 17, the cover 28 is formed to have a U-shaped section including a clamp 29 forming a column-shaped space and a slit 30 extended downward from the clamp 29. In the clamp 29, there is snugly inserted a deformed cylindrical connector 10. In this connector 10, here are formed two circular holes 12 of an internal diameter, which are vertically juxtaposed to each other. These holes 12 are individually extended linearly to the left and right side faces of the connector 10. In the connector 10, moreover, there is formed a straight slit 31 which is extended from a portion of the outer circumference of the connector 10 to connect the holes 12.
One end portion of the second heat pipe 15 is inserted from the left side of FIG. 16 into the hole 12, as positioned below. On the other hand, one end portion of the first heat pipe 13 is inserted from the right side of FIG. 16 into the hole 12, as positioned above. As a result, the first heat pipe 13 and the second heat pipe 15 are so held in the connector 10 as can turn on the center axis with their containers closely contacting with each other at their side faces. Here, the leading end portions of the individual heat pipes 13 and 15 are arranged inside of the left and right side faces of the cover 28.
In this cover 28, there are formed three communication holes 32 which are extended to the left and right of FIG. 17 through the slit 30. These communication holes 32 are formed to have a smaller internal diameter at their longitudinal intermediate portions than at the two end portions. Nuts 34 are arranged through compression washers 33 at the right side portions, as seen in FIG. 17, of the individual communication holes 32. Into the left side portions of the individual communication holes 32, on the other hand, there are inserted bolts 36 through compression washers 35. These bolts 36 and the nuts 34 are individually fastened to each other. In short, the bolts 36 and the nuts 34 correspond to a fastening jig of the present invention.
As the bolts 36 are fastened, the gap of the slit 30 of the cover 28 is narrowed to reduce the internal diameter of the clamp 29. Then, the gap of the slit 31 of the connector 10 is narrowed to compress the connector 10 radially. As a result, the outer circumferences of the individual heat pipes 13 and 15 are fastened by the inner circumferences of the individual holes 12. When the bolts 36 are loosened, on the other hand, the connector 10 is righted from its deflected state to lighten the forces for fastening the individual heat pipes 13 and 15. In short, the fastening degrees of the individual heat pipes 13 and 15 by the connector 10 can be finely adjusted by the bolts 36. In other words, the sliding resistance accompanying the turning actions of the individual heat pipes 13 and 15 can be finely adjusted if the fastening forces of the bolts 36 and the nuts 34 are adjusted.
Here will be enumerated still another example of the connector 10. As shown in FIGS. 18 and 19, the circular hole 12, as located above, is extended through the connector 10 but fails to reach the left side face thereof, as seen in FIG. 18. On the other hand, the circular hole 12, as located below, is extended through the connector 10 but fails to reach the right side face, as seen in FIG. 18.
Between the two side face portions of the connector 10 and the leading end faces of the individual holes 12, there are fitted O-rings 37 of rubber, which are fitted in the inner circumferences of the individual holes 12. Thus, the connector 10 is equipped at its individual side face portions with the O-rings 37. These O-rings 37 are provided for preventing the air from stealing into the gaps between the holes 12 and the individual heat pipes 13 and 15. Here, this connector 10 is not provided with any slit for providing the communication between the holes 12. The remaining construction is substantially identical to that of the connector shown in FIGS. 16 and 17.
When the bolts 36 are fastened, the gap of the slit 30 is narrowed to reduce the internal diameter of the clamp 29. Accordingly, the connector 10 is radially compressed, and the individually O-rings 37 are radially deformed to narrow the gaps between the outer circumferences of the individual heat pipes 13 and 15 and the inner circumferences of the holes 12. In other words, the individual heat pipes 13 and 15 are fastened by the individual holes 12. As a result, there are raised the sliding resistance which accompany the turning actions of the individual heat pipes 13 and 15. Then, the individual O-rings 37 are elastically deformed to avoid the radial deformations of the individual heat pipes 13 and 15.
When the bolts 36 are loosened, on the other hand, the deformed connector 10 is radially righted to lighten the force of the connector 10 for fastening the individual heat pipes 13 and 15. Then, the deflected O-rings 37 are righted to prevent the air acting a heat resistance from stealing into the gaps between the holes 12 and the individual heat pipes 13 and 15.
Here will be described an embodiment in which the first heat pipe and the connector act as the hinge. Into the hole 12 positioned above, as shown in FIG. 20, there is inserted from the right side one end portion of the first heat pipe 13. This first heat pipe 13 is so held in the connector 10 as can freely rotate on its center axis. This connector 10 is so attached along the edge portion to the personal computer body 1 that the end portion of the first heat pipe 13 held thereby is arranged in a horizontal position with respect to the bottom portion of the personal computer body 1. Here, the personal computer body 1 and the display 7 are equipped with neither the support blocks 5 and 8 nor the hinge pins 6, that is, not the hinge 9 for supporting the display 7 to be erected/inclined.
The other end portion of the first heat pipe 13 inserted from the lower edge, as seen in FIG. 20, of the personal computer body 1 into the personal computer body 1 and is extended along the lower edge to the left of FIG. 20 such that it is arranged along the left edge, as seen in FIG. 20, of the electromagnetic shielding sheet 14. Moreover, the first heat pipe 13 is firmly attached to the electromagnetic shielding sheet 14 by the not-shown suitable means. In short, the display 7 is so supported by the personal computer body 1 as to be erected/inclined by the relative rotation between the connector 10 and the first heat pipe 13. In other words, the first heat pipe 13 and the connector 10 act as the hinge 9.
According to the cooling device for the notebook personal computer described above, therefore, the support blocks 5 and 8 and the hinge pins 6 can be dispensed with. This raises an advantage that the construction of the display 7 and the personal computer body 1 can be made simpler than that shown in FIG. 1. | A cooling device for a notebook personal computer which has a personal computer body accommodating an exothermic electronic element and a display hinged in an openable/closable manner to the personal computer body through a hinge mechanism, including a first heat pipe having a first end portion arranged along the display and a second end portion arranged in parallel with a center line of rotation of said hinge mechanism; a second heat pipe having a first end portion arranged on the electronic element in a heat transferable manner and a second end portion arranged in thermal contact with the second end portion of said first heat pipe; and a connector defining a first hole having an axis and configured to receive the second portion of the first heat pipe, a second hole having an axis different from the axis of the first hole and configured to receive the second portion of the second heat pipe, the first and second holes communicating with each other; wherein at least one of the second end portions is positioned on the center line of rotation of the hinge mechanism. The connector and one of the heat pipes, having a relatively rotatable second end portion, can form a hinge between the personal computer body and the display. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a vehicle transmission, in particular for utility and agricultural vehicles, in which the speed changing arrangement (for example, a multi-speed gearbox and a range gearbox) is followed by a central differential which divides the gearbox output power between the front axle and the rear axle. Agricultural tractors of this type frequently have their front and rear axles fitted with unequally large tires.
2. Description of the Related Art
Despite varied proposals, current four wheel drives for agricultural tractors are not entirely satisfactory. With a rigid drive to the front and rear axles with zero overrun for the front axle, field operation results in propulsion forces that are too low and negative propulsion forces when operating around curves.
One way to reduce this effect is to increase the overrun to 2% or more, but there are still problems in operation around curves. As the steering angle increases, the front wheel on the inside of the curve increasingly loses its overrun and the slip changes from positive to negative. This means that the wheel is retarded and no longer propels the vehicle. In operation around curves this means the turning radius actually increases when the mechanical front wheel drive (MFWD) is engaged. In operation on the road the result is increased tire wear and, in the field, shearing of the grass shoulder. This is particularly apparent in the tight turns approaching the headland of a field.
One possible solution to this problem is to disable the front wheel drive for on the road operation. Unfortunately, this in turn means that the front axle cannot be utilized for propulsion or engine braking.
In theory, this disadvantage could be partially avoided by automatically engaging the front wheel drive during braking when the gearbox is in the road operation range. However, this might result in uncontrollable operating conditions.
Further attempts at solving the problem include adding steps in the gear ratios for the front wheel drive, while disabling the outer front wheel using a non-slip differential or the like. This has the disadvantages that it strains the transmission to the front wheel, may cause difficulty in controlling shifting between pulling and braking, and it limits drive to only three of the four wheels of the tractor.
EP-B1-0 112 421 and EP-B1-0 113 490 have disclosed vehicle transmissions of the aforementioned type with central differentials, by which the engine torque can be divided in a predetermined ratio between the front axle and the rear axle. This avoids strains between front and rear axles.
It is known to use spur gear planetary gearsets as central differential gears, but they require considerable radial space with their planets, carriers and ring gears. Since their gear ratio depends largely on the conditions of the installation, the central differentials limit the design possibilities for the vehicle transmission. If the central differential is applied in connection with a synchronized gearbox, for example, its radial dimensions must be compatible with the established shaft spacing of the synchronized gearbox. This requirement is not always met easily, particularly with compact gearboxes with high power density.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a vehicle transmission of the aforementioned type in which the problems described above are overcome. In particular the central differential should not unduly limit the spacial design constraints of the vehicle transmission. The vehicle transmission should require relatively little technical sophistication and permit manufacture at low cost.
These and other objects are achieved according to the present invention by using as the central differential a gearset (referred to herein as a "Ravigneaux gearset") having two co-axial sun gears, a single planetary carrier, and two sets of planetary gears mounted to the planetary carrier with the gears of each set of planetary gears meshing with the gears of the other set of planetary gears and with one of the sun gears. The output torque of the gearbox output is divided corresponding to the ratio of the radii of the two sun gears of the Ravigneaux gearset for transmission to the front and rear axles.
In comparison to known central differentials, a Ravigneaux gearset can be applied in relatively small radial dimensions, since the normal ring gear and overlapping input can be eliminated.
This advantage is particularly evident in an embodiment in which the gearbox transmission output is transmitted to the Ravigneaux gearset coaxially through its planet carrier and in which the output of the Ravigneaux gearset is through its two sun gears. With such a structure and with the central differential arranged in the primary driveline of the vehicle, the small radial dimensions of the Ravigneaux gearset make for a compact design of the vehicle transmission.
If the central differential is operated at its design point, then the coupled planetary gears do not rotate with respect to the planet carrier. This in turn means that the output shafts to the front and rear axles rotate synchronously and carry torques that correspond to the static gear ratio. Differential action takes place in operation around curves when the rear wheels force the front wheel to rotate faster because it is running on a larger circle. Front and rear axles then operate according to their designed torque ratios.
In view of the differing application requirements and load conditions of the vehicle, in particular an agricultural tractor, this ideal condition cannot be attained in each case. In plowing, for example, 80 to 100% of the engine torque must be delivered by the rear wheels, while for transport operations a division of 35% to the front axle and 65% to the rear axle would be preferred.
Therefore a preferred embodiment of the invention proposes that the central differential be selectively shiftable by a clutch arranged between the operating shafts of the Ravigneaux gearset for the front and rear axles. With the clutch in differential mode, the central differential free-wheels and the torque is divided between the front and rear axles in proportion to the radii of the sun gears. With the clutch in block mode, the front and rear wheel drives are coupled to each other so that the central differential is locked and becomes ineffective. In block mode, the torque division is the result of the transmission capabilities of the wheels and depends on the conditions of the ground (for example, whether the vehicle is on a non-skid surface or slippery ground). In block mode, the drive relations therefore correspond to those of known mechanical front wheel drive (MFWD) clutch systems, where the front and rear axles are sometimes rigidly connected to the output shaft of the drive.
It is particularly preferable to arrange the clutch between the two output shafts to extend coaxially from one side of the central differential.
In contrast to the previously known MFWD drives, in which the all-wheel drive must be disengaged under certain operating conditions, for example, at high speeds and in sharp curves, the all-wheel drive according to present the invention can remain engaged at all times. A control arrangement to engage and disengage the all-wheel drive therefore is unnecessary.
In agricultural tractors, the front wheels typically are significantly smaller than the rear wheels. This means they have a smaller contact area and therefore exhibit greater slip than the rear wheels. Compensation also is necessary for the differing rolling distances around curves. It therefore is advantageous that to design drive to the front axle with a certain overrun (2 to 5%) with respect to the rear wheels. The overrun can be incorporated into the driveline following the central differential (transmission compensation). With such a built in overrun, the block mode described above results in the same operating conditions as in known agricultural tractors.
A further advantage of building in an overrun for the front axle is that it means that whenever the central differential is operating in differential mode, it constantly rotates at a relative speed, even in travel straight ahead. Due to this constant differential compensation, the gears of the differential rotate relative to each other. This avoids transmission of the torque primarily through one pair of gear teeth and excessive wear of those teeth.
A control arrangement is appropriately provided that can automatically lock the central differential in critical operating conditions, for example, high slip due to front wheels on ice. Thus the positive connection is not lost either in driving or in braking.
The clutch can be designed advantageously as a safety clutch for the front axle. This can be attained, for example, by the selection of the number of clutch disks and the pressure of the clutch, where the slip torque of the clutch is so designed that no more than the torque capacity of the front axle is transmitted.
A particularly preferred embodiment of the invention provides that the final stage of the speed changing arrangement include at least one planetary gear whose gear ratio can be shifted. This planetary gear configured as gearbox end stage acts as range gear following a multi-speed gearbox. Preferably this controllable planetary gear also contains a Ravigneaux gearset.
A very compact configuration in which energy is transferred in the smallest space and at low manufacturing cost is attained by integrating the central differential and the controllable planetary gearset into a combined circulating gear drive. Here both gearsets preferably are provided with common components. A common planet carrier is most appropriate here to carry the planet gears of both the controllable planetary gear and the central differential. Preferably the controllable planetary gear is provided with a driven sun gear, two ring gears and a planet carrier used as output. In addition a first clutch between the first ring gear and the gearbox housing and a second clutch between the sun gear and a second ring gear are arranged for shifting between two gear ratios. For example, actuating the first clutch may engage the field range, and the second clutch may engage a road range. Furthermore a third clutch may be arranged between the first ring gear and the second ring gear with which a reverse range may be engaged.
The main gearbox ahead of the final stage, for example, a multi-speed gearbox, is preferably a continuously variable gearbox, but may also be a shift operated synchronized gearbox or one that can be shifted under load. If the main gearbox uses a synchronized shifted gearset, a continuously variable gearset or a gearset that can be shifted under load, it produces an output torque through an output shaft to the final stage which, for example, is configured as a range gearset. With a continuously variable main unit, the range gearbox may, in addition, be driven by at least a second input shaft. Here there is a particular advantage in configuring the final stage of the gearset as a compound gearbox with at least two inputs. This makes it possible to design the complete vehicle transmission as a continuously variable, shift-controlled drive.
The advantage of a continuously variable gearbox as main drive over a synchronized gearbox or a gearbox shifted under load, lies in the fact that the shift components of the gear ratios to be shifted rotate at synchronous speeds at the shift point, so that no shocks occur during the shift such as those found in a gearbox shifted under load. On the other hand a synchronized gearbox cannot be shifted under load.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described with reference to the drawings, in which:
FIG. 1 shows a schematic view of a central differential coupled to a fully synchronized transmission according to the present invention.
FIG. 2 shows a schematic cross section of a Ravigneaux gearset.
FIG. 3 shows a schematic view of a continuously variable shift gearbox with a following synchronized range gearbox and central differential.
FIG. 4 shows a schematic view of a continuously variable shifted gearbox followed by combined range gearbox and central differential.
FIG. 5 shows a schematic view of an overlapping gearbox with two output shafts and following integrated range gearbox and central differential.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the figures described in the following corresponding parts are designated by the same reference numerals.
The vehicle transmission shown in FIG. 1 is generally composed of a fully synchronized shifted gearbox, a fully synchronized range gearbox and a central differential. The internal combustion engine 10 of a vehicle, not shown in any further detail, is connected through a main clutch 12 to the gearbox input shaft 14 of the shifted gearbox on which free gears 16, 18, 20 are supported. Double-acting shift sleeves 22 and 24 can selectively connect the free gears 16, 18, 20 with the input shaft 14. A countershaft 26 carries four gears 28, 30, 32, 34, fixed against rotation, of which the second gear 30 and the third gear 32 mesh with the free gears 18 and 20 and form the first and second gear ratios, respectively, when engaged by the corresponding shift sleeves 22, 24. The first free gear 16 engages the fixed gear 28 of the countershaft 26 through a reverse gear 38 supported in the gearbox housing 36 and forms the reverse gear ratio.
The second shift sleeve 24 can connect the gearbox input shaft 14 with a range gearbox input shaft 40 which carries four fixed gears 42, 44, 46, 48, which results in the third gear ratio. The countershaft 26 and the range gearbox input shaft 40 are in constant mesh through the fixed gears 34 and 42.
A range gearbox output shaft 50 carries four free gears 52, 54, 56, 58 that mesh with the fixed gears 42, 44, 46, 48 on the range gearbox input shaft. They can be selectively connected by double-acting shift sleeves 60, 62 with the shaft 50, whereby four ranges can be selected.
In addition the range gearbox output shaft 50 supports the planet carrier 64 of a Ravigneaux gearset 66 which operates as central differential. The planet carrier 64 is fixed against rotation relative to the shaft 50 and supports a set of long planet gears 68 and a set of short planet gears 70. Each planet set may, for example, consist of three gears of which, however, only one gear 68, 70 is shown. In addition the Ravigneaux gearset 66 contains two sun gears 72, 74 whose coaxial output shafts 76, 78, extend through the Ravigneaux gearset 66.
The output shaft 76 of the larger sun gear 72 is connected to a bevel gear 80 of a differential gear of the rear axle, not shown. The output shaft 78 of the smaller sun gear 74 is configured as a hollow shaft, through which the output shaft 76 extends. It carries a gear 82 which is connected with a gear 84 of the front wheel drive shaft 86 that drives the front axle, not shown. The two drive shafts 76, 78 can be connected to each other by a clutch 88 so that the differential action of the Ravigneaux gearset 66 is suppressed.
The engagement of the various gears of the Ravigneaux gearset 66 is shown in FIG. 2. The planet carrier, which is not detailed further, carries three long planet gears 68 and three short planet gears 70, free to rotate. The long planet gears 68 mesh with the larger sun gear 72 and the short planet gears 70 mesh with the smaller sun gear 74. Furthermore, the long planet gears 68 mesh with the short planet gears 70.
If the larger sun gear 72, for example, were rotated with the planet carrier 64 at rest, then the other, smaller sun gear 74 would be rotated in the opposite direction by means of the long planet gears 68 and the short planet gears 70. At the same time there would be an increase in rotational speed corresponding to the diameter ratio of the sun gears 72, 74. This mode of operation is what makes use of the Ravigneaux gearset as a differential gear possible.
When the Ravigneaux gearset 66 is driven through its planet carrier 64 there is a division of the torque applied to the output shafts 76, 78 of the two sun gears 72, 74 corresponding to the ratio of the diameters of the sun gears 72, 74.
The synchronized shifted gearbox of FIG. 1 is replaced in FIG. 3 by a continuously variable hydrostatic-mechanical power distributing drive. Such a drive has been described in detail in the German patent application, file number P 41 15 623.4 and will not be described further herein.
The output shaft of the hydrostatic-mechanical drive of FIG. 3 is simultaneously the input shaft 100 of a synchronized range gearbox. The gear 104 is rigidly connected to the shaft 100 and drives the intermediate shaft 114 through the gear 116. The shift sleeve 102 can alternately connect the output shaft 106 of the range gearbox with the input shaft 100 directly or indirectly through the intermediate shaft 114. The intermediate shaft 114 also carries fixed gears 118, 120, while the output shaft 106 carries two free gears 108, 110 which can be selectively connected by shift sleeve 112 to the output shaft 106. Fixed gear 118 meshes free gear 108 on the output shaft 106, while a reverse gear 122 is arranged between the other fixed gear 120 and the further free gear 110 on the output shaft 106.
The first shift sleeve 102 permits a shift between road range on the one hand and field or reverse range on the other. The second shift sleeve 112 permits a shift in the range gearbox between field range and reverse range.
The output shaft 106 of the range gearbox is connected to the planet carrier 64 of a Ravigneaux gearset 66. The Ravigneaux gearset 66 is arranged in the same way as that described in connection with FIG. 1, so further description here can be dispensed with. In contrast to FIG. 1, according to FIG. 3, an intermediate gear 124 is interposed between the gear 82 connected to the output shaft 78 of the smaller sun gear 74 and the gear 84 of the front drive shaft 86 by means of which the distance between the shafts 86 and 106 can be increased and the direction of rotation can be reversed.
The vehicle transmission shown in FIG. 4 differs from the transmission shown in FIG. 3 in the arrangement of the range gearbox, which is configured here as a shifted planetary gearset. The core of this planetary gearset can be shifted under load by means of several clutches.
The output shaft 100 of the hydrostatic-mechanical drive carries the sun gear 130 of the shiftable gearset, fixed against rotation relative to the shaft 100. Furthermore a planet carrier 132 is supported on this shaft 100, free to rotate. The planet carrier 132 carries a set of long planet gears 134 and a set of short planet gears 136, each of which meshes with a ring gear 138, 140, respectively. The planet gears 134, 136 of a set mesh with each other in a fashion similar to that described in connection with FIG. 2.
The ring gear 138, which meshes with the set of long planet gears 134, can be locked by a brake 142 to the gearbox housing 36, while the ring gear 140, which meshes with the set of short planet gears 136, can be locked by a brake 146 to the gearbox housing 36. The ring gear 140, which meshes with the set of short planet gears 136, also can be connected by a clutch 144 to the input shaft 100.
If the clutch 144 is engaged while the brakes 142 and 146 are released, then the range gearbox 126 operates in block mode. This defines the road range. If the brake 142 is locked at the same time that the clutch 144 is disengaged and the brake 146 unlocked, the drive shifts from the road or reverse range into the field range. By locking the brake 146 and simultaneously disengaging the clutch 144 or releasing the brake 142 the drive shifts from the road or the field range into the reverse range.
The planet carrier 132 of the range gear box is coupled to the planet carrier 64 of the Ravigneaux gearset 66 which is operating as the central differential gear. Thus, this planet carrier is a combination part that carries the planet gears 68, 70, 134, 136 of both gearsets 66, 126.
The vehicle transmission shown in FIG. 5 is similar to the drive shown in FIGS. 3 and 4, but differs from the transmissions described so far in that the range gearbox 150 is not driven by one input shaft (such as the shaft 100 in FIG. 4), but is instead driven by two input shafts 152 and 154. The rotational speeds of the input shafts 152, 154 result from an overlapping gearbox 156 that may be variously configured and that will not be described here in detail. Suitable examples would be the types of gearboxes described in FIGS. 3 and 4.
The overlapping gearbox 156 is located between the drive unit 158 and an output drive 160 formed by the range gearbox 150 and the central differential 66.
A significant fact in this case is the division in block A of the power of the engine carried in shaft 162 into a mechanical portion with generally constant rotational speed in the shaft 164 and a continuously variable portion that is preferably hydraulic which is carried in shaft 166. In this case the block A represent a hydraulic pump, and the block B a hydraulic motor. The continuous variation may, however, be accomplished by other means, such as a variable chain drive.
The shaft 164 drives the gear 168, so that the mechanical portion of the power is preferably transmitted at constant rotational speed from the shaft 164 through the gears 168 and 170 to the hollow shaft 172.
The portion of the power that is continuously variable in rotational speed is carried by the shaft 166. The mechanical and hydraulic portions of the power can be further converted in the overlapping gearbox 156, before they are again combined in the output drive 160.
In the road range a clutch 174 is engaged to connect the hollow shaft 154 with the ring gear 138, and the torques of the solid shaft 152 and the hollow shaft 154 are joined by the compound gearbox 150. The rotational speed is continuously variable and with equal speed on the hollow shaft 154 and solid shaft 152 the gearbox 150 operates in block mode. Thereby the two drive shafts 152 and 154 replace the clutch 144 of FIG. 4.
When a clutch 176 is engaged to connect the hollow shaft 154 with the ring gear 138 and the clutch 174 is disengaged the result is a second range of gear ratios. The rotational speed of the shaft 154 is generally constant, while that of the shaft 152 is variable, so the two ranges result from subtraction or addition of rotational speed with respect to the common coupling point.
While the invention has been described in conjunction with a specific embodiment, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the appended claims. | A vehicle transmission, particularly for industrial and agricultural vehicles, includes a speed change gearset (gear and range) and a central differential for distributing the gearset output to the front and rear axles of the vehicle. The central differential is formed of a Ravigneaux gearset to reduce the dimensions of the transmission and to minimize the costs and technical resources required to produce it. The Ravigneaux gearset distributes the torque of a gear output shaft to the front and rear axles according to the ratio of the two planetary sun gear diameters. Preferably, the end stage of the speed change gearset is formed by a further gearset, and the planet carriers of both Ravigneaux gearsets are formed as a common structural member carrying the planets of both Ravigneaux gearsets. | 5 |
[0001] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/101,400, filed on Sep. 22, 1998, pursuant to 35 U.S.C. Sections 111 and 119(e).
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to contamination inspection for semiconductor wafers and the like and in particular to a system which inspects both the frontside and backside of a semiconductor wafer without manual or automatic inversion of the wafer.
[0004] 2. Description of the Related Art
[0005] Tools used in the semiconductor wafer manufacturing process must periodically be checked to determine whether they must be replaced or are still in usable condition. The condition of a tool is checked by inspecting wafers processed by that tool for defects. Bare wafers are typically routed through the process tool with the frontside facing up, and wafer defects detected optically by illuminating portions of the wafer and measuring the amount of illuminating light scattered by defects on the wafer surface.
[0006] Previously, systems which performed inspection of wafers did so in two discrete stages. First, the frontside of the wafer was scanned for contamination caused by the process tool. If the defect rate on the frontside of the wafer was acceptable, the wafer was then turned over to inspect the backside for further particle contamination and other defects. The process tool was considered usable if the defect rate on the backside of the wafer was also acceptable.
[0007] Inspection of both sides of a wafer by these procedures accordingly required time for inspection of one side, examination of the one side, inverting the wafer without excessively damaging the wafer, scanning the reverse side, and examining the results of the second side scan. In addition to this excessive amount of time required for examination, the process of flipping the semiconductor wafer had a tendency to contaminate the edges of the wafer due to surface or edge contact with a gripping device. In some processes, when the wafer was flipped over to inspect the backside, the front side of the wafer could be contaminated by the flipping process. The resulting contamination of the frontside of the wafer tends to render the wafer unsuitable for further processing. Thus, all test wafers were usually scrapped after each inspection, reducing overall productivity and increasing per unit cost.
[0008] Edge handling of wafers has also complicated the problem. As wafers tend to suffer from contamination or other degradation when handled by wafer orientation systems, the handling of a wafer requires special care. Although previous wafer orientation systems have included multiple drive rollers, radially inwardly-biased contact rollers, and a tiltable wafer-supporting table with an air-bearing mechanism, each of these handling methods have benefits and drawbacks. Systems without multiple drive rollers and radially inwardly-biased or spring-loaded contact rollers cannot maintain steady wafer rotation rate during the portion of a cycle in which the drive roller is not in contact with the round edge of the wafer because the drive roller loses traction along the wafer edge.
[0009] In inspection equipment, it is important to maintain steady rates of wafer rotation to avoid errors in defect detection, such as errors in detecting defects where none exist, or simply failing to detect defects. Previous systems which supported semiconductor wafers through direct contact with a solid surface present special problems during inspection since contact with the support surface may increase contamination or move defects from one location to another in ways that render the wafer unsuitable for future processing.
[0010] It is therefore an object of the current invention to provide a system for minimizing the time required for full inspection of both the front side and back side of a wafer.
[0011] It is another object of the current invention to provide an arrangement which minimizes overall wafer contamination during the inspection process, particularly when inspecting both front and back sides of the wafer.
[0012] It is a further object of the current invention to minimize edge handling concerns, such as contamination, during the inspection of the front side and back side of a wafer.
[0013] It is still a further object of the current invention to minimize the number of defects missed or falsely detected by the inspection system.
SUMMARY OF THE INVENTION
[0014] According to the present invention, there is provided an apparatus that simultaneously inspects the frontsides and backsides of semiconductor wafers for defects. The inventive system disclosed herein may also read tracking information imprinted on the backsides of the semiconductor wafers.
[0015] The invention rotates the semiconductor wafer while the frontside and backside surfaces are generally simultaneously optically scanned for defects. Rotation is induced by providing contact between the beveled edges of the semiconductor wafer and roller bearings rotationally driven by a motor.
[0016] In the present invention, a semiconductor wafer is supported such that the semiconductor wafer lays flat during the inspection process. The surface is large enough to accommodate the wafer as well as the rollers for rotating the wafer and the means for holding the wafer. The wafer is preferably supported in a tilted or semi-upright orientation such that support is provided by gravity. This tilted supporting orientation permits both the frontside and the backside of the wafer to be viewed simultaneously by a frontside inspection device and a backside inspection device. The backside of the wafer for purposes of this invention is the side of the semiconductor wafer by which the wafer is being supported. Simultaneous dual-side inspection of the front side and back side of the wafer effectively doubles the throughput of inspection equipment and eliminates the need to turn the semiconductor wafer over during the inspection process, thereby reducing the opportunity for edge contamination of the inspected wafer.
[0017] The wafer is rotated by multiple motor-driven roller bearings. These drive rollers are positioned at the circumference of the wafer and are angled such that the roller pads contact the wafer only along the beveled edge. This periphery positioning and rotation coupled with angular contact between the rollers and wafer edge and surface permits inspection of the entire surface and significantly reduces the potential for contamination of the surface resulting from edge contact, or contact with the roller pads.
[0018] The drive rollers are spaced apart such that at least one of the two drive rollers spaced farthest apart contacts the round edge of the wafer throughout the rotation cycle. This constant contact feature ensures that the rotation rate of the wafer is suitably steady during defect inspection. Also, the steady rotation rate minimizes the number of defects missed or falsely detected by the inspection system.
[0019] The wafer rotation rate is such that roller contact does not damage the wafer edge. Furthermore, defects are not carried or transported from one part of the edge to another. Moreover, the rate should be controlled so as to minimize slip between the roller and the wafer edge. The present invention is intended for use at wafer rotation rates on the order of 400 revolutions per minute. Unlike previous systems, the present invention does not exhibit excessive vibration for defect inspection purposes at these rotation rates. The increased wafer rotation rate also increases the throughput of inspection equipment.
[0020] The semiconductor wafer is held against the drive rollers by pressure using a set of undriven roller bearings (contact rollers) or alternatively simply using gravitational force by tilting the wafer and inspection surface. This pressure ensures that the drive rollers hold traction on the beveled wafer edge so that a steady rotation rate can be maintained. All contact rollers thereby maintain contact with the edge of the semiconductor wafer throughout the rotation cycle.
[0021] Prior to inspection, the system locates the edge registration feature, commonly called the “flat”. The system detects the specific position of the wafer using the edge registration feature either by measuring the position of the contact rollers, or by connecting the contact rollers to switches which are turned on when the contact rollers are touching a flat registration edge calibration switch. Once the flat registration edge or notch is located, the system rotates the wafer to desired orientations for inspection purpose by controlling the drive rotors.
[0022] Other objects, features, and advantages of the present invention will become more apparent from a consideration of the following detailed description and from the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 illustrates a perspective view of the preferred embodiment of the invention in an unloaded state;
[0024] FIG. 2 presents a perspective view of the preferred embodiment of the invention loaded with a semiconductor wafer to be inspected;
[0025] FIG. 3 is a perspective view of the preferred embodiment of the invention with the semiconductor wafer loaded and the table surface tilted in the scan position;
[0026] FIG. 4 is a plan view of an arrangement including the loaded semiconductor wafer, roller bearings and scan head elements;
[0027] FIG. 5 presents a perspective view of the scan head CCD detector elements arranged in relation to the surface of the semiconductor wafer during backside inspection; and
[0028] FIG. 6 illustrates a perspective view of an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIGS. 1-3 present various views of the invention in the loaded and unloaded states. From FIG. 1 , the background contamination inspection device is initially in its unloaded state, or without a semiconductor wafer located thereon. The semiconductor wafer is supported by a substantially flat table surface 101 . The substantially flat table surface 101 is equipped with an air-bearing mechanism 102 upon which the semiconductor wafer may be floatably supported to eliminate contamination of the backside by contact with the table surface 101 . The table surface 101 is mounted to a fixed base 103 such that the table surface 101 can tilt about an axis 104 defined at a side edge of the table surface 101 . Four wafer load pins 105 a - 105 d are mounted on the table surface 101 such that they can retract and temporarily maintain the wafer. The wafer load pins 105 a - d are located in a circular pattern concentric with the air-bearing mechanism 102 and semiconductor wafer which is to be loaded. Furthermore, the wafer load pins 105 a - d are located proximate the round edge of the semiconductor wafer to be loaded.
[0030] Roller bearings 106 a - d are rotatably mounted on the table surface 101 in an orientation substantially equivalent to the angle or axis 104 about which the table surface 101 is tilted. Roller bearings 106 a - d are further arranged in a circular pattern having substantially the same center as the air-bearing mechanism 102 and the semiconductor wafer to be loaded such that the radius of the smallest circle simultaneously tangent to all of the roller bearings 106 a - d is equal in length to the radius of the semiconductor wafer to be loaded. AS shown in FIG. 1 , roller bearings 106 a and 106 b are driven by motors (not shown) and are separated by such a distance that both cannot simultaneously contact the flat, or registration edge, in the semiconductor wafer. Thus roller bearings 106 a - d provide continuous driving of the wafer when loaded thereon.
[0031] Prior to inspection, the system locates the-edge registration feature, commonly called the “flat”. The system detects the specific position of the wafer using the edge registration feature either by measuring the position of the contact rollers, or by connecting the contact rollers to switches which are turned on when the contact rollers are touching a flat registration edge calibration switch. Once the flat registration edge or notch is located, the system rotates the wafer to desired orientations for inspection purpose by controlling the drive rotors.
[0032] The scan head 107 is situated within the table channel 108 . Table channel 108 passes completely through the top and bottom surfaces of table surface 101 . The table channel 108 is symmetric about the radius of the semiconductor wafer and is of such length that the scan head 107 may travel from a position directly beneath the center of the semiconductor to a position directly under the outer edge of the wafer. The preferred scan head is shown in greater detail in FIG. 4 .
[0033] FIG. 2 shows the preferred embodiment of the invention having the semiconductor wafer 201 loaded thereon. The semiconductor wafer 201 is floatably supported by the air-bearing mechanism 202 . During the loading process, the wafer load pins 206 a - d hold and center the semiconductor wafer 201 over the air-bearing mechanism 202 . Once the operator or software determines that the semiconductor wafer 201 is centered over the table surface 201 , the wafer load pins 206 a - d are partially retracted and no longer contact the edge of the semiconductor wafer 201 .
[0034] FIG. 3 shows the background contamination-inspection device in scan position. The table surface 101 in FIG. 3 has been tilted to a predetermined angle about axis 304 . The driven roller bearings 306 a and 306 b are continuously kept in contact with the wafer edge by the gravitational force acting on the semiconductor wafer 301 due to tilting. The tilting of the semiconductor wafer 301 permits high speed rotation of the semiconductor wafer and minimizes the amount of pressure exerted on the edge of the wafer 301 while still ensuring that at least one drive roller maintains contact and traction along the edge of the wafer throughout the wafer rotation cycle. Edge contact is therefore minimized since no undriven contact rollers are needed.
[0035] The wafer loading pins 305 a - d are fully retracted when the invention is in the scan position and thus only contact the semiconductor wafer during the loading phase of the inspection. The wafer loading pins 305 a - d do not contact the wafer during rotation or while the system is in the inspection phase.
[0036] Once the semiconductor wafer 301 has been loaded onto the table surface 301 , the wafer loading pins 305 a - d are retracted, the table surface 301 tilted as shown in FIG. 3 , and the drive rollers 306 a and 306 b are turned to rotate the semiconductor wafer 301 . The semiconductor wafer 301 is rotated by the motor (not shown) turning the drive rollers 306 a and 306 b. Positioned within the table surface 301 is the scan head 307 (not shown) which traverses in a linear manner to scan the backside of the semiconductor wafer 301 , i.e. the side of the wafer adjacent to the table surface 301 . The scan head 307 is positioned within the table surface channel 308 such that the orientation of the scan head 307 does not change relative to the semiconductor wafer 301 as the table surface 301 is tilted to the position shown in FIG. 3 . During rotation of the table surface 301 , the scan head 307 translates linearly within table surface channel 308 in a parallel orientation with respect to the bottom surface of the semiconductor wafer 301 . While the semiconductor wafer 301 rotates adjacent to the wafer table 301 using drive rollers 306 a and 306 b, the scan head 307 translates within the table surface channel 308 , moving from the edge of the semiconductor wafer 301 to the center thereof, or vice versa.
[0037] Various tilting angles may be employed in the current system while still within the scope of the present invention. The current desired tilting angle for the table surface is 45 degrees, but higher angles may be used successfully depending on the speed of the rotation of the semiconductor wafer 301 and the size and particularly weight of the wafer 301 . For example, an excessively high angle between the table surface 301 and the horizontal may cause the wafer 301 to fall away from the table surface, while a relatively small angle between the table surface 301 and the horizontal may cause the wafer 301 to lose contact with the drive rollers 306 a and 306 b. It is therefore preferable to maintain the angle of tilt within the range of 15 degrees from horizontal to 75 degrees from horizontal.
[0038] FIG. 4 illustrates the backside inspection process. Backside inspection is preferably performed using the double-dark field method. Roller bearings 404 are rotated by a drive motor (not shown) to induce rotation of the semiconductor wafer 401 . The roller bearings 404 illustrated in FIG. 4 represent an alternate orientation of the roller bearings from those shown in FIGS. 1-3 . The roller bearings 404 of FIG. 4 and the undriven roller bearings 405 may be originally oriented away from the table surface (not shown) for purposes of loading the wafer 401 onto the table surface, and then the driven and undriven roller bearings may be repositioned adjacent the wafer 401 to provide sufficient but not excessive contact between the bearings 404 and 405 and the wafer 401 . The orientation of the elements illustrated in FIG. 4 contemplates a horizontal and untilted arrangement of the wafer and bearings, but the optical elements of FIG. 4 may be used in the tilted orientation of the invention illustrated in FIGS. 1-3 .
[0039] In FIG. 4 , the wafer 401 maintains contact with both the driven roller bearings 404 and the undriven roller bearings 405 . During operation, as-semiconductor wafer 401 rotates, the scan head 407 (not shown), including laser illuminator 402 and sensor 403 , travels along the table surface channel (not shown) in close proximity to the surface being scanned. The sensor 403 may include one or more CCD detector elements. The laser illuminator 402 projects an elongated illuminating beam onto an area roughly 50 μm×10 mm in size, illustrated by the illuminated patch 406 in FIG. 4 , on the surface of the semiconductor wafer 401 at a non-normal angle of incidence.
[0040] FIG. 5 shows the arrangement of the CCD detector elements relative to the semiconductor wafer 501 . The illuminator (not shown) projects collimated beam 502 through cylindrical lens 503 onto illuminated patch 504 on the surface of the semiconductor wafer 501 . CCD detector elements 505 are symmetrically located on either side of and parallel to the incident plane (the plane formed by the intersection of the wafer surface normal and the illumination path). The CCD detector elements 505 are linear and produce a serial read-out which corresponds to the amount of scattered light received by the detector. This output is used to determine whether a defect exists at the particular section of the wafer being examined. Using this information, the system determines whether the wafer 501 may be used in further processing. If the system determines that the wafer 501 is not usable, the process tool must be replaced and the wafer 501 is scrapped. If the wafer 501 is usable, the defect location information for the particular wafer is stored with its tracking number. The wafer 501 is then placed back in the processing stream and the process tool is not replaced.
[0041] FIG. 6 illustrates an alternate, stand-alone embodiment of the present invention. In this embodiment, the table surface 601 is affixed to base 603 . Base 603 is mounted to support legs 602 such that the base 603 may be rotated about axis 604 . Scan head 607 is fixedly mounted to arm 605 , and arm 605 is attached to turning screw 606 . Turning screw 606 is rotationally coupled to a motor (not shown).
[0042] Rotation of turning screw 606 causes arm 605 and scan head 607 to move laterally along the table surface channel 608 , parallel to the backside of semiconductor wafer 611 in its tilted state (as shown) or untilted state. This motion of the scan head 607 permits scanning of the back side of the semiconductor wafer 611 . The semiconductor wafer 611 is rotated by contact with roller bearings 609 which are driven by a motor (not shown). The semiconductor wafer 611 also maintains contact with roller bearing 610 (second roller bearing not shown), which is undriven. The contact with undriven roller bearing 610 is due to gravitational force being exerted on the semiconductor wafer 611 . Thus the orientation of the wafer, as shown, is in constant contact with the rollers and may be inspected on both front and back sides.
[0043] While the invention has been described in connection with specific embodiments thereof, it will be understood that the invention is capable of further modifications. This application is intended to cover any variations, uses or adaptations of the invention following, in general, the principles of the invention, and including such departures from the present disclosure as come within known and customary practice within the art to which the invention pertains. | A system for simultaneously inspecting the frontsides and backsides of semiconductor wafers for defects is disclosed. The system rotates the semiconductor wafer while the frontside and backside surfaces are generally simultaneously optically scanned for defects. Rotation is induced by providing contact between the beveled edges of the semiconductor wafer and roller bearings rotationally driven by a motor. The wafer is supported in a tilted or semi-upright orientation such that support is provided by gravity. This tilted supporting orientation permits both the frontside and the backside of the wafer to be viewed simultaneously by a frontside inspection device and a backside inspection device. | 6 |
CROSS-REFERENCE TO RELATED CASE
This application is a divisional application of my commonly assigned, United States application Ser. No. 943,526, filed Sept. 18, 1978, entitled "DEVICE FOR MONITORING YARN MOTION ON A TEXTILE MACHINE", now U.S. Pat. No. 4,256,247, granted Mar. 17, 1981.
BACKGROUND OF THE INVENTION
The present invention refers to a novel device for monitoring motion, particularly ballooning motion, of a thread or yarn travelling on a textile machine, the device comprising sensing means producing an electrical sensing signal when contacted by the travelling yarn. The invention also relates to electronic circuitry for processing said electrical sensing signal.
Swiss Pat. No. 457,228 discloses an electronic yarn monitor mounted at a winding machine wherein the travelling yarn performs a traversing motion, and a sensor is arranged in the traversing area. The embodiments of this patent comprise optical and capacitive sensors. Further there is stated that several sensors may be located in the traversing area. The travelling yarn due to the traversing motion produces an A.C. voltage which disappears upon yarn break or standstill and thus is indicative of yarn motion.
Swiss Pat. No. 583,656 discloses dynamoelectrical sensing devices adapted for monitoring the motion of oblong or extended objects, such as threads or yarns. Most of these known sensing devices are designed as hollow cylindrical structures comprising at least one insulating guide body, ground and signal electrodes, and a yarn passageway. The ground and signal electrodes extend over the entire circumference of the insulating guide body. The formation of the sensing signal is based on the effect that high frequency electrical signals having noise character are produced by the friction occurring between travelling thread and insulating guide body.
SUMMARY OF THE INVENTION
It is a primary object of the invention to provide a sensing device for monitoring ballooning motion of travelling threads or yarns.
It is another object of the invention to provide such sensing devices adapted to produce A.C. voltage sensing signals.
It is a more specific object of the invention to provide sensing devices for producing modulated high frequency sensing signals, and electronic circuitry transforming such sensing signals into demondulated or D.C. output signals.
Now in order to implement the aforementioned objectives and others which will become more readily apparent as the description proceeds, the sensing device of the invention comprises a yarn guide structure forming a yarn channel surrounding the travelling yarn and provided with yarn motion responsive and non-responsive elements arranged in alternate sequence at said yarn guide structure in circumferential direction of the yarn channel.
In the following context the invention is illustrated referring to schematic drawings which represent various sensing devices and an electronic circuitry for evaluating the sensing signals. The connections attached to the electrodes are not shown for the sake of clearness.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will be apparent upon consideration of the following detailed description thereof which makes reference to the annexed drawings wherein:
FIGS. 1a and 1b show a hollow cylindrical sensing device in schematic plan view and side elevation;
FIGS. 2a and 2b illustrate an embodiment of a pigtail sensing device in plan view and axial cross-section;
FIGS. 3a and 3b show a hollow cylindrical sensing device comprising two electrodes in plan view and side elevation;
FIGS. 4a and 4b show a similar sensing device of different electrode structure in plan view and axial cross-section;
FIGS. 5a and 5b represent a ring-shaped sensing device provided with two electrodes in plan view and axial cross-section along the line V--V in FIG. 5a, respectively;
FIGS. 6a and 6b show a sensing device provided with an insert gap in plan view and cross-sectional view along the line VI--VI of FIG. 6a, respectively;
FIG. 7 represents a simple embodiment of an electronic evaluation circuitry in block schematic; and
FIG. 8 comprises signal diagrams illustrating the operation of the evaluation circuitry of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
In the following context referring to FIGS. 1a, 1b through 6a, 6b the sensing elements furnishing electrical sensing signals on passage of a ballooning thread are termed collector electrodes.
With reference to FIGS. 1a and 1b the sensing device comprises a hollow cylindrical yarn guide body 1 surrounding a yarn channel K, and a collector electrode 11 attached to the exterior surface of yarn guide body 1. Collector electrode 11 extends in axial direction of yarn channel K over the entire length of yarn guide body 1, however in peripheral direction only over part of the latter forming a sector of about 60°. The remaining portion which is not covered by collector electrode 11 forms a neutral zone which does not substantially contribute to the sensing signal.
FIGS. 2a and 2b show a pigtail yarn guide or yarn guide body 2 of conventional shape made of ceramics and provided with a collector electrode 21 at the interior surface or wall surrounding yarn channel K. Collector electrode 21 extends over about one quarter of the periphery of yarn channel K. FIG. 2b shows an axial cross-section along the line II--II in FIG. 2a wherein the dashed lines F show the yarn path or limitation of the balloon. R and R' refer to the sections of the friction zones intersected by the plane of the drawing, along which friction zones the ballooning yarn is contacting yarn guide body 2. As may be seen from FIG. 2b collector electrode 21 is arranged at the interior surface of yarn guide body 2 immediately above friction zone R', thus avoiding wear of the edge portions of collector electrode 21.
FIGS. 3a and 3b show a sensing device comprising a hollow cylindrical yarn guide body 3 bearing two diametrically arranged collector electrodes 31, 31' on the interior surface thereof, and two diametrically arranged ground electrodes 32, 32' at the exterior surface. All the electrodes extend over a sector of about 45° in peripheral direction and over the entire length of yarn channel K of yarn guide body 3 in axial direction. Each of the ground electrodes 32, 32' and the corresponding collector electrode 31 and 31' cover an equal sector in such a manner that the collector electrodes are shielded by the ground electrodes 32, 32'.
Referring to FIGS. 4a and 4b a collector electrode 41 and a ground electrode 42 are arranged at a small distance d from each other on the interior surface of a hollow cylindrical yarn guide body 4, thus forming a small gap S4 between them. Those electrodes 41, 42 are small in the direction of the periphery of yarn channel K and extend over the entire length of yarn guide body 4 in axial direction. Ring-shaped friction zones R and R' are located at the lower and upper ends, respectively, of yarn channel K and yarn guide body 4.
In FIGS. 5a and 5b there is represented a ring-shaped sensing device comprising a yarn guide body 5 at whose interor surface there are arranged a collector electrode 51 and a ground electrode 52 succeeding one another in axial direction. Between those electrodes there is a small gap S5 extending in peripheral direction of yarn channel K. The dashed lines F indicate the yarn path or limitation of the balloon.
The sensing devices shown in FIGS. 1, 3 and 4 are symmetrical relative to a length middle plane thereof and comprise a friction zone R or R' at each end of yarn channel K as shown in FIG. 4b, so that these devices may be mounted irrespective of the direction of their longitudinal axes.
The yarn guide bodies 1-5 are preferably made from a hard electrically insulating material, such as ceramic oxide. The electrodes may advantageously be covered by a hard layer for protecting the same against wear by the running yarn. By way of example the electrodes may be made by plasma plating.
The sensing devices shown in FIGS. 1-5 may be modified in various manners. When the collector electrodes are arranged on the interior surface of the yarn guide body surrounding yarn channel K, the yarn guide body may comprise a metallic core provided with a hard insulating cover. Such a metallic core may be used as a ground electrode simultaneously shielding the collector electrode.
FIG. 6a shows an essentially rectangular sensing device comprising, as may be seen from FIG. 6b, three plate-shaped structural elements 60, 61 and 62 in sandwich arrangement. The lower plate 61 is made of metal and serves as a collector electrode. The latter has the shape of an L whose interior edge is represented by the dashed line 61a. The upper essentially rectangular plate 62 which also consists of metal serves as a basic structural element and ground electrode, and is provided with a circular recess or bore having at one side thereof an opening at K1. Yarn channel K is mainly confined by the circular interior edge of plate 62 and by a section K1 of the interior edge of lower plate 61. The plates 61 and 62 are interconnected by an intermediate plate 60 made of insulating material. Intermediate plate 60 is also L-shaped and has a short leg whose right edge is in register with the edge 62a of the upper plate 62. Thus a free space serving as an insert gap E is provided at the right side of edge 62a and between the plates 61 and 62 allowing insertion of a thread or yarn in radial direction into yarn channel K. The upper plate 62 is provided with an extension 63 having a bore 64 for mounting the sensing device on a machine. As may be seen from FIG. 6a, the yarn channel K is confined by the plate-shaped electrodes 61, 62 in alternate sequence.
This embodiment of the sensing device may advantageously be used in the place of the one shown in FIGS. 2a and 2b for sensing a ballooning yarn and producing a signal indicative of a ballooning motion only during time intervals in which the yarn is contacting collector electrode 61 at the edge K1 thereof beneath insert gap E.
That embodiment may be modified variously and accommodated to any use in question. By way of example the upper plate 62 may be made of an insulating material rather than metal, or it may be covered by a hard insulating material. Collector electrode 61 may also be provided with a hard insulating layer. Preferably ceramic oxide of great surface hardness is used as an insulating material for this purpose.
In an alternative embodiment there may be attached to the lower plate 61 serving as a sensing element a piezoelectrical element 65 which may be vibrated by the mechanical vibrations of the exposed portion of plate 61 when the latter is contacted by the travelling yarn, whereby an electrical sensing signal shaped as an A.C. pulse series is generated.
The electronic evaluation circuitry shown in FIG. 7 not only serves for monitoring yarn travel but also for surveying the frequency of the ballooning motion of a yarn, that is the frequency of the rotation of the yarn section forming the balloon, e.g. on a ring-spinning machine or balloon forming twisting machine. This evaluation circuitry is of particular importance with double twisting machines of the type in which a thread is drawn from a delivery bobbin over a slowly rotating flyer to the top of a thread insert tube, and from the top thereof downwards to the lower end of the tube. From this lower end, the yarn is conducted over a quickly rotating disk outwards, then forming a quickly rotating balloon section extending upwards into a yarn guide, and therethrough passing to a take-up spool.
In the event of a yarn break in the balloon forming yarn section it may occur that the upper broken yarn end drags along the above-mentioned thread end conducted by the slowly rotating flyer. In this event yarn is further drawn off the delivery bobbin through the yarn guide, however at a "wrong", slow ballooning frequency in the range of about 1-2 Hz. This wrong operation cannot be detected by a conventional yarn travel monitor or balloon monitor, however will be discovered by the frequency evaluation circuitry as described in the following context.
The evaluation circuitry comprises a series connection of six stages connected to a collector electrode 11, comprising an A.C. amplifier 6, rectifier 7, low-pass filter 8, high-pass filter 9, integrator 10 and terminal stage 20. The evaluation circuitry is designed such that the terminal stage 20 produces no output signal as long as the ballooning frequency of the yarn remains within a predetermined range, however terminal stage 20 is actuated and furnishes an alarm signal and/or a signal for stopping the machine as soon as the frequency decreases below a predetermined lower limit, or the yarn breaks. Thus the evaluation circuitry also functions as a yarn break monitor.
It is to be understood that high-pass filter 9, integrator 10 and terminal stage 20 together function as a frequency discriminating means. These stages 6-10 may be designed in conventional manner and thus need not be described in detail. Terminal stage 20 may be a power stage actuating a relay or an indication device.
The mode of operation of the evaluation circuitry shown in FIG. 7 is illustrated, by way of example, by FIG. 8. Assuming the ballooning frequency is in the range of 100-200 Hz, e.g. 150 Hz, with the undisturbed run of the machine. The signals produced in the single stages 6-10 of the evaluation circuitry are shown in the diagrams at A of FIG. 8 and labelled 6'-10'. The A.C. amplifier 6 produced high frequency pulses 6' of the repetition rate 150 Hz as sensing signals. The pulses 7' produced by the following rectifier 7 are transformed by low-pass filter 8 into a pulsing D.C. voltage 8'. Low-pass filter 8 may have an upper cut-off frequency of e.g. 500 Hz. The demodulated signal 8' passes substantially unchanged high-pass filter 9 whose lower cut-off frequency may be 20 Hz. The output signal 9' of high-pass filter 9 is transformed by integrator or smoothing stage 10 into a D.C. voltage 10' which is supplied to terminal stage 20.
Now when the frequency of the ballooning motion is substantially below the lower cut-off frequency 20 Hz of high-pass filter 8 there results the pulse sequence shown in diagrams B. The demodulated sensing signal, that is the output signal 8' of low-pass filter 9, exists as a pulsing D.C. voltage of very low frequency, however this signal 8' is suppressed by high-pass filter 9 and the output signal of the integrator 10 becomes zero.
By such an evaluation of the high frequency sensing signal 6' produced by the sensing device 6, a normal or correct sensing signal 6' as shown at A in FIG. 8 is demodulated into a signal 8' pulsing with a low frequency of 150 Hz, that is a normal ballooning frequency. However, by the following filtration in high-pass filter 9 the above-mentioned "wrong" ballooning frequency of 1-2 Hz as shown at B in FIG. 8 is suppressed and thus detected by the evaluation circuitry as a failure.
In place of a further filtration by high-pass filter 9 which together with low-pass filter 8 forms a band-pass, the demodulated signal 8' may be supplied to a pulse counter, frequency counter or the like frequency discriminating means.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practised within the scope of the following claims. Accordingly, | An electronic circuitry for evaluating electrical sensing signals furnished by a sensing device responsive to ballooning motion of a yarn in a textile machine and delivering a series of high frequency pulses having a repetition rate corresponding to the low frequency of the ballooning motion, comprises a series arrangement of an A.C.-amplifier, a rectifier, a low-pass filter having an upper cut-off frequency smaller than said high frequency but greater than the low frequency of the ballooning motion, and a frequency discriminator made up of a high-pass filter and integrator, and a final stage to either indicate improper yarn ballooning or disable the machine operation. | 3 |
REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under U.S. Provisional Application Ser. No. 60/737,210, filed 16 Nov. 2005.
TECHNICAL FIELD
[0002] The present invention relates to paperboard for use in manufacturing paperboard cartons. More particularly, the invention relates to methods and apparatus for coating paperboard with compositions to make the paperboard particularly suitable for use in manufacturing water resistant and other types of packaging.
BACKGROUND OF THE INVENTION
[0003] Paperboard cartons are often used for packaging beverage containers cans and bottles. During packaging, cold or chilled beverages containers may be placed into the cartons and condensation from the air may form on the containers and drip onto the inside surfaces of the paperboard carton. This may weaken the carton, or cause reduced adhesion of external coatings resulting in deterioration or rub-off of graphics printed on the external coatings.
[0004] To protect against moisture absorption, the inside of the paperboard carton may be coated with a waterproofing or water resisting material. However, such materials reduce the adhesion of sealants used upon the flaps of the paperboard carton, so that the integrity of the carton may be compromised. To retain sealant adhesion, it is desirable that the waterproofing material be selectively applied to the interior surface of the paperboard, with the material not applied to areas intended for gluing. For other purposes, selective application may typically be done by a printing method, such as flexographic, rotogravure, or offset printing, but such methods typically cannot apply sufficient coat weights of the waterproofing material. Coat weights in range of 2.5 lb/1000 ft 2 are required, which can be applied by technologies such as rod coating used in papermaking, but these typically coat the entire surface. A method is desired that will allow the waterproofing material to be selectively applied at the higher coat weights that are typically achieved by paper machine coaters.
SUMMARY OF THE INVENTION
[0005] The present invention provides a method whereby sufficiently high coat weights of waterproofing materials are applied to the “inside” surface of a paperboard intended for use as a packaging material. Selected areas of the inside surface, preferably those areas to be glued, are left without the waterproofing material, in order to provide superior glue adhesion.
[0006] A method for producing a paperboard product having separate coated and uncoated areas is provided, in which a substrate web is moved over a rotating applicator roll so as to define a region of contact between the web and the roll. A coating material is applied to the surface of the applicator roll at an application location remote from the region of contact. A coating removal device is positioned adjacent the roll between the application location and the region of contact to remove a portion of the coating material from at least one area on the roll. Contact between the web and the roll transfers the coating material to the web, creating a coated surface except for a stripe corresponding to the portion of the coating material removed the said roll.
[0007] The method may include removing the coating material by a wiping action. The coating removal device may include a doctor blade disposed in contact with the surface of the roll.
[0008] The coating material may be applied in the roll by positioning a coating reservoir containing the coating material adjacent to the roll at the application location so that the surface of the roll contacts the coating material.
[0009] The applicator roll may also include at least one recessed area defined in the surface of the roll, whereby no contact is made between the roll and the web along said recessed area, thereby defining an uncoated area on the web corresponding to the recessed area.
[0010] In accordance with another embodiment of the invention, a method for producing a paperboard product having separate coated and uncoated areas includes the steps of extruding a coating material from an extruder having an elongated slot for the coating material to create a film of coating material. A portion of the slot is blocked to create a gap in the film of coating material. The film of coating material is then applied to a substrate web to produce a coated substrate web with at least one uncoated area thereon.
[0011] In accordance with still another embodiment of the invention, a method for producing a paperboard carton blank includes moving a substrate web over a rotating applicator roll so as to define a region of contact between the web and the roll. A coating material is applied to the surface of the applicator roll at an application location remote from the region of contact. A coating removal device is positioned adjacent the roll between the application location and the region of contact to remove a portion of the coating material from at least one area on the roll. Contact between the web and the roll transfers the coating material to the web, creating a coated surface except for a stripe corresponding to the portion of the coating material removed from the roll. A carton blank is then cut from the web so that an uncoated area of the blank is formed from substrate located along the stripe.
[0012] The uncoated area of the blank may be used to form the flaps of the carton.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a typical prior art coating process;
[0014] FIG. 2 illustrates an embodiment of the invention directed to providing uncoated stripes on a paperboard product;
[0015] FIG. 3 illustrates a paperboard carton blank with uncoated areas intended for gluing;
[0016] FIG. 4 illustrates an alternative embodiment of the invention directed to providing patterned uncoated areas on a paperboard product.
DETAILED DESCRIPTION
[0017] FIG. 1 illustrates a typical coating process. An applicator roll 110 rotates in a pan 120 containing a coating material 122 . The rotation of the applicator roll 110 through the coating material 122 results in a film of coating material upon the surface of the applicator roll 110 in the region indicated at 124 . A web 150 , for example of paper or paperboard, moves in contact with applicator roll 110 , causing part of the coating film to be transferred onto the web 150 , for example in a contact area or meniscus 126 .
[0018] Typically there may be an excess of coating deposited onto the web. To remove excess coating, a device such as rod 130 may be placed in contact with web 150 . The rod 130 may be supported by rod bed 135 . A backing roil 140 may be provided to form nip between the backing roll 140 and the rod 130 , through which the web 150 passes, thus removing excess coating from the web, as shown by excess coating 137 draining away from the rod 130 , and back into pan 120 . Finally, the coated web 150 ′ continues on, for example to a drying process.
[0019] In accordance with a preferred embodiment of the invention, FIG. 2 illustrates a method for providing an uncoated stripe on a web. To accomplish this, a holder 210 holds a wiper 220 against the applicator roll 110 , so that the coating material film 124 may be wiped clean from the applicator roll as shown by area 230 . The wiper 220 may be a rigid, semi-rigid, or flexible device, for example a doctor blade, squeegee, wiper, roller, air blast, etc. When the web 150 contacts the applicator roll 110 , the web is left with a dry stripe 235 . Upon contact with the rod 130 , there may be some spreading of the coating upon the web, but typically there will still remain a dry stripe on the web in the machine direction, as evidenced by an area 240 of no excess wipe-off by the rod 130 . It may be necessary to use a short series of trials to determine the best placement and width of wiper 220 in order to provide the correct width of the final dry stripe 237 upon web 150 . The wiper 220 may be supported upon a support beam 215 , from whence its position may be adjusted. More than one wiper may be used to give multiple dry stripes.
[0020] The coated web may be used in the manufacture of paperboard articles such as cartons. The web 150 ′, after leaving the coating apparatus may be wound into a roll and transported to separate equipment for carton manufacture. Alternatively, the coating apparatus may be incorporated into the carton manufacturing equipment. In such a case, the web 150 ′ may be fed into one or more printing stations where the web is printed using flexographic, gravure, or other printing methods on the side opposite the applied coating 124 . The printed web is then directed into cutting equipment that cuts printed carton blanks from the moving web.
[0021] FIG. 3 illustrates the formation of two paperboard carton blanks 300 , 302 from the coated web. Although only two are shown for illustration purposes, typically several blanks would be fitted in the cross direction of a paperboard web, and hundreds or thousands would fit in the machine (long) direction of a paperboard web. The blanks may be offset slightly in the long direction (as shown) in order to minimize waste of the paperboard material. The carton blanks have flaps 310 that are typically folded and glued during assembly. These flaps 310 fit in areas 320 , 322 , 324 that are not coated. The non-flap portions of the carton blanks fit in areas 330 , 332 that are coated, for example with a waterproofing material. The coating may preferably extend partway onto the flaps 310 provided uncoated area sufficient for gluing is left uncoated on the tabs. However, depending on the carton design, the coating areas 330 , etc may be narrower or wider than shown.
[0022] In addition to imparting water resistance or water proofing, the coating .may impart additional strength to the carton blank, and allow the use of lighter weight or lower caliper paperboard. The coating may itself provide strength, or may prevent loss of strength that may occur if the paperboard were to become wetted.
[0023] Carton blanks with portions coated to provide desirable properties (such as water resistance or wafer proofing) and other portions not coated to provide other desirable properties (such as superior gluability) may also be produced by methods such as extrusion coating. For example, to create uncoated stripes using an extrusion coater, portions of the extruder die slot may be closed, for example with blocks, to prevent flow from those areas of the slot. An extrusion coating upon exit from a die may exhibit “die swell” and upon travel from the die to the substrate may exhibit “neck-down”, either of which may cause the width of the uncoated stripe to differ from the width of a block in the die opening. Simple experimentation will suffice to determine the appropriate block width to achieve the desired uncoated stripe width.
[0024] FIG. 4 illustrates an alternate embodiment for the present invention in which further areas of the web may be left uncoated. This can be particularly useful, e.g., if a transverse region of a carton blank is to be used for gluing. The apparatus is the same as that shown in FIG. 2 , except that a recess 350 is formed into the surface of applicator roll 110 to correspond to the desired uncoated area. As roll is rotated through the coating material 122 , either no coating material will adhere to the roll on the recess 350 , or if it does, it will be carried at the bottom of recess 350 . In either case, no coating will be transferred to web 150 in this area, with the result that an uncoated area 360 will be formed repeatedly in a corresponding pattern on web 150 ′. By properly selecting and positioning one or more recesses 350 on roll 110 , the desired uncoated pattern may be produced.
[0025] Suitable coating materials are known to those skilled in the art. Such materials may be selected based upon the desired properties to be achieved by coating. For example, such coatings may be used to provide enhanced water resistance, grease or oil resistance, or improved tearing strength.
[0026] Methods of making and using the paperboard and the paperboard carton in accordance with the invention should be readily apparent from the mere description as provided herein. No further discussion or illustration of such products or methods, therefore, is deemed necessary.
[0027] While preferred embodiments of the invention have been described and illustrated, it should be apparent that many modifications to the embodiments and implementations of the invention can be made without departing from the spirit or scope of the invention. Although the preferred embodiments illustrated herein have been described in connection with a paperboard structure with a waterproofing material applied in a pattern through a particular coating process, these embodiments may easily be implemented in accordance with the invention in other structures or to by other application methods.
[0028] It is to be understood therefore that the invention is not limited to the particular embodiments disclosed (or apparent from the disclosure) herein, but only limited by the claims appended hereto. | A method of producing paperboard and cartons made therefrom is described incorporating a waterproof or water resistant coating applied to the interior of the carton except for areas intended for gluing. A coating material ( 122 ) is applied to the surface of an applicator roll ( 110 ), and a portion of the coating material is then removed from the roll. Contact between a paperboard web ( 150 ) and the roll transfers coating material to the web, creating a coated surface except for an uncoated stripe ( 237 ). A carton blank ( 300 ) may be formed from the coated web with the uncoated portion of the carton blank cut from the uncoated stripe. | 3 |
BACKGROUND OF THE INVENTION
This invention relates generally to a bimetal actuated lock for a lid or door and more particularly is directed to a lock for the lid or door of a laundry appliance such as a washing machine where the lock is actuated automatically when the machine is in operation to prevent opening of the lid or door while the spin tub is rotating at a high rate of speed.
Washing machines, whether of the top loading or front loading type, have two general modes of operation. During the wash mode, the movement of the parts is generally at a rather slow speed to cause the relative movement of the clothes and the wash liquid, and at this speed no particular danger is likely to result if the lid or door were opened and the operator were to place a hand or other object inside the machine, since such machines have an electrical interlock which de-energizes the motor whenever the door or lid is opened. However, when such machines are in the spin cycle in which as much liquid is removed from the clothes as possible, the spin tub is rotating at a high rate of speed and with the load of wet clothes represents a relatively large magnitude of angular momentum. Under these conditions, if the lid or door is opened, the operation of an interlock switch to de-energize the motor is insufficient to bring the parts to a stop quickly and if a person were to reach into the machine under those conditions, severe injuries could result.
In view of this problem, two approaches have been used as a safety feature. One of these is to utilize a brake in the drive mechanism which is automatically actuated upon de-energization of the motor by the interlock to apply a positive braking action and bring the rotating spin tub to a halt as quickly as possible. However, the brake mechanism is rather expensive and subject to wear after an extended period of time, which tends to decrease its effectiveness and cause a longer period of time to elapse before the spin tub is completely stopped.
The other approach to solving this problem is to use a locking device to positively prevent the opening of the lid or door of the washing machine whenever the spin tub is rotating. This can be accomplished by the use of a solenoid-operated lock which positively engages the door as long as the solenoid is energized and then releases the door after the tub is stopped to allow access to the interior of the washing machine. It has been recognized that a solenoid-type locking device has shortcomings not only because of the high cost and reliability question of the solenoid itself but also the need to provide extra contacts on the timer to provide the necessary time delay after the motor has been de-energized for the spinning tub to come to a stop.
An alternative to the solenoid locking device has been proposed in the form of a lock which is actuated by a bimetallic element which is heated by the current passing through the drive motor. Such a device has been disclosed in the present inventor's U.S. Pat. No. 4,074,545 granted Feb. 21, 1978. A similar device is also shown in U. S. Pat. Nos. 4,179,907 and 4,286,811. With this locking arrangement, the high inrush current when the motor is energized causes a large current to flow through the bimetal element to rapidly heat it so that the latch blade will move rapidly into a locking condition. When the motor is de-energized, the thermal lag in such a device causes the locking blade to remain in the engaged position for a period of time for the bimetal element to cool off and the parameters of operation can be adjusted so that the blade remains in the locking position for a sufficient period of time for the spin basket to come to a complete stop. However, it has been recognized with this prior bimetal lock, that the parameters must be chosen such that it will actuate and heat to a temperature sufficiently high that cooling will take a long enough time that the lock will not disengage before the spin tub stops under any load conditions. Thus, the lock must be designed to work with a minimum load, and when the machine is used with a heavy load, particularly one that has a relatively high imbalance, the increased motor torque and hence current through the lock will tend to noticeably increase the unlocking time.
SUMMARY OF THE INVENTION
The present invention provides a lock mechanism in the form of a bimetallic electrothermal actuator to be positioned adjacent a door opening on an appliance such as a top loading washing machine, where the lock mechanism is placed directly underneath the top adjacent an edge of the door opposite from the side on which it is hinged. There is a small opening in the top through which a latch member carried by the cover extends when the door is in a closed position. The lock mechanism includes an interlock switch which is actuated by the latch member when the door is in the closed position to close the contacts of the normally open interlock switch, which prevents operation of the machine when the door is open. Normally, in a top loading washing machine, the lock mechanism is connected electrically through the programmed timer so that it is in series with the drive motor only when the motor is programmed to go into the spin mode. The interlock switch then acts to prevent energization of the motor in the spin mode except when the door is in the closed position. The door lock and interlock are normally not connected in the circuit by the timer when the washing machine is in an agitate mode or other portion of the cycle when access to the interior is not considered dangerous.
The lock mechanism includes a lock lever which is arranged to engage the latch member on the lid to positively prevent the lid from being open when the lock lever is engaged. Actuation of the lock lever is controlled by a bimetallic element which may generally be constructed and arranged as shown in the aforesaid U.S. Pat. No. 4,074,545. Thus, when the lid or cover is in the closed position with the interlock switch closed when the program timer goes into a spin mode, the drive motor is energized through the interlock switch and the bimetal element which is heated by its own resistance as the full current for the drive motor passes through it. Because of the high starting current of the drive motor, there is a high inrush current through the bimetallic element which allows it to heat up rather quickly and respond to provide the necessary movement so that the lock lever will engage the latch mechanism very quickly before the spin basket in the washing machine has accelerated to a high rate of speed.
When the lock lever reaches substantially full engagement with the latch member on the cover, movement of the lock lever closes a pair of switch contacts that are connected electrically across the bimetal element, thereby shunting or shorting out the bimetal element so that substantially no current passes therethrough. When this is done, the bimetal element is no longer heated by the current flowing through it and it will begin to cool down and tend to move the lock lever toward the unlocked position. However, before the lock lever moves any substantial distance, the shutting contacts are opened to allow full current to again pass through the bimetal element, thereby heating it up and moving the lock lever back toward the fully locked position. Thus, as long as the motor current is passing through the lock unit, as determined by the operation of the timer, the lock member will oscillate back and forth, in locking engagement with the latch member, with the shunting contacts continually opening and closing.
Although the shunt switch contacts may open and close cyclically all during the time that the washing machine is in the spin mode, and thus may be required to carry relatively high currents depending upon the load on the drive motor, the contacts operate at very low effective voltage. Because the bimetal element has a relatively low resistance, the voltage drop across this member will be insignificant as compared to the voltage applied to the drive motor. The fact that the shunt contacts carry a high current but at a low voltage minimizes any arcing at these contact points as they open and close, and thereby can provide relatively long life for the unit despite a high number of opening and closing cycles for the contacts.
As a result of the operation of the shunting contacts of this invention, the heating, and hence deflection, of the bimetal element is limited to a predetermined maximum regardless of the absolute value of the current passing through the drive motor. The construction and arrangement of the bimetallic element and the shunt contacts may thereby be selected for proper operation under the lowest drive motor run currents, and if such current is substantially increased because of a larger and perhaps highly unbalanced load in the spin tub, the unlocking time will remain constant since the deflection and temperature of the bimetal is limited by the operation of the shunting contacts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary, exploded, perspective view of the lid lock according to the present invention as installed in a top loading washing machine;
FIG. 2 is a top plan view, with parts broken away, of the lock mechanism of FIG. 1;
FIG. 3 is a side elevational view, with parts broken away, of the lock mechanism as installed in a washing machine;
FIG. 4 is a bottom view of parts broken away of the lock mechanism;
FIG. 5 is a side elevational view of the lock mechanism opposite from that of FIG. 3; and
FIG. 6 is a fragmentary circuit diagram showing the operation of the shunt contacts of the lock mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in greater detail, there is shown the lid lock 10 according to the preferred embodiment of the present invention. While the lid lock 10 can be used in a number of different applications, it is shown, for purposes of illustration only, as being particularly adapted to lock the lid or cover of a top loading automatic washing machine in the closed position while the machine is in a spin condition where the spin tub 19 rotating at a high rate of speed for centrifugal water extraction from the clothes. The lid lock 10 has an integral mounting flange 11 by which it is secured underneath the washing machine top panel 12 in a suitable manner. The top panel 12 has a recess 14 around the opening giving access to the spin tub and a hinged cover or lid 15 is mounted in the recess 14 by hinges (not shown) on the opposite side. Thus, the cover lid 15 can move upward or downward out of or into the recess 14 to close off the opening.
Attached to the underside of the lid 15 is a latch member 16, which, when the lid is in the closed position extends downward through an opening 17 in the recess 14. The latch member 16 in turn has an opening 18 at its lower end positioned so that when the lid 15 is in the closed position, the opening 18 on latch member 16 will be below the surface of the recess 14.
As shown in greater detail in FIGS. 2-5, the lid lock 10 is an electrothermal actuator which includes a suitable casing or frame 20 formed of an electrical insulating material. A pair of electrical terminals 22 and 23 project from the side of casing 20 beneath the mounting flange 11 and provide the electrical connection to the rest of the circuitry of the washing machine.
On the other side of casing 20 is mounted a switch lever 25 having a rotatable shaft 26 journalled in the casing 20 to rotate about an axis parallel with the top panel 12. The switch lever 25 also includes an arm 27 extending adjacent the opening 17 where it has a bent end portion 28 extending beneath opening 17, so that when the lid 15 is closed, the end of the latch member 16 will engage the bent end portion 28 to rotate the switch lever 25 in a downward direction. The shaft 26 extends through the interior of casing 20 where it includes a cam arm 31 extending in the opposite direction from the arm 27, and which serves to mount a coil-type biasing spring 32 which surrounds the shaft 6 and is anchored at one end to the casing 20 and at the other end to the cam arm 31 to bias the switch lever to a position where the arm is adjacent the top panel 12.
Within the casing 20, the one terminal 22 has a terminal extension 34 which extends above the cam arm 31 where it carries a contact 35 which is therefore rigidly mounted in position. Also mounted on casing 20 is a bracket member 37 on the lower end of which is mounted a flexible contact arm 38 which extends adjacent the terminal extension 34. On contact arm 38 is mounted a contact button 39 adapted to make electrical contact with the contact button 35 on terminal extension 34. The contact arm 38 extends beyond contact 39 to form an offset portion 41 extending underneath the cam arm 31. The flexible contact arm 38 is normally biased so that the contacts 35 and 39 are in electrical contact to make continuity therethrough. However, the biasing force of bias spring 32 is sufficient to rotate the shaft 26 so that the switch lever arm 27 is moved to a raised position and the cam arm 31 engages the offset portion 41 so as to move the flexible contact arm 38 downward with contact 39 out of engagement with the other contact 35. However, when the lid is closed, the latch member 16, because of the weight of the lid, forces the end portion 28 and arm 27 downward against the force of bias spring 32 so that the cam arm 31 rises and allows the natural resiliency of contact arm 38 to bring the contacts 39 and 35 into engagement.
A bimetal element 44 is mounted in the casing 20 to lie in a substantially vertical plane and is anchored to the casing 20 at the end away from latch member 16. The bimetal element 44 consists of a plurality of parallel extending legs arranged to provide a continuous current path to provide for uniform heating, and hence uniform deflection, of all of the legs together. Thus, a first leg 46 is secured to the bracket 37 and a first end 47 at the opposite end is connected to a second leg 48 extending back to a base portion 49 secured to a mounting lug 50 carried on the casing 20. A third leg 51 extends from the lug 50 to terminate in a second end 52 connected to a fourth leg 53 which extends back to a terminal lug 54 carried on the casing 20. As shown in FIG. 5, the electrical circuit is completed by an external wire 56 on the outside of casing 20 extending from the terminal lug 54 back to the other terminal 23. From this it will be seen that when the switch lever 25 is depressed by the latch member 16, there will be electrical continuity from the one terminal 22 through the contacts 35 and 39 to the bimetal element, where the current in turn passes through the first, second, third and fourth legs to the terminal lug 54 and hence back to the other terminal 23. When the current passes through the terminals the bimetal element will then be heated and the first and second ends 47 and 52 will then be heated and the first and second ends 47 and 52 will then be deflected in a direction toward the side of the casing 20 carrying the terminals 22 and 23.
To provide the locking action as a result of the deflection of the bimetal element 44, a vertical shaft 61 is rotatably journalled in the casing 20 and secured thereto is a pivot block 62 rotatable with the shaft 61. The pivot block 62 has a pair of vertically spaced recesses 63 adapted to receive projecting fingers 66 on the bimetal ends 47 and 53. Thus, deflection of the bimetal element through the connection of the pivot block 62 will cause the vertical shaft 61 to rotate. Accordingly, a locking lever 68 is carried on the upper end of shaft 61 outside of the casing 20 and projects toward the latch member 16, where it carries a projecting tip 69 adapted to move into the opening 18 to prevent opening of the cover. Thus, when the bimetal element is in the unheated condition, the legs will be undeflected and the locking lever will be in a position where the tip 69 is spaced away from the latch member. However, when the cover is closed and the electric motor is energized to cause current to flow through the bimetal element, the lever 68 will be rapidly deflected so that the tip 69 enters the opening 18 and by interconnection between the locking lever 68 and the underside of the top panel 12, it is not possible to raise the cover 15 as long as the tip 69 is in locking position.
As explained hereinabove, the construction of the bimetal element must be such that under a minimal load condition when there is a minimal current through the drive motor, the bimetal element must be heated by that current to assume a sufficient deflection that the tip 69 will enter the locking opening 18 on latch member 16. Since the motor operates from a stopped condition at the start of a spin cycle, there will be a high starting current and the bimetal element 44 will be heated with sufficient rapidity, in the order of one or two seconds, for the locking tip 69 to engage the latch member. The problem encountered with prior art devices, however, is that in the event that the running current for the motor is quite high, there will be a tendency for the bimetal element, as a result of the continued flow of such higher current, to be deflected more than the optimum amount. Although the locking lever 68 is limited in its range of movement, once the tip 69 enters opening 18, the bimetal element will flex further under the higher current. When the spin cycle ends and current flow stops, this additional heating and flexing of the bimetal results in a longer unlock time.
The present invention overcomes this problem by providing a shunt switch arrangement which shorts out the bimetallic element whenever the tip 69 is in full engagement with the opening 18. To accomplish this, a flexible electric contact arm 72 is mounted at one end on a depending leg 71 which is an integral part of bracket 37. The contact arm 72 extends adjacent the vertical shaft 61 where it carries a contact 73 on the side facing the casing side 20 on which the terminal 22 and 23 are mounted. Accordingly, terminal 23 has a downwardly extending extension 76 on the inside of casing 20 which carries an electrical contact 77 in alignment with the contact 73. A projecting arm 79 carried on vertical shaft 61 at the lower end is so positioned that when the vertical shaft 61 is rotated to a position where the blocking lever tip 69 is in full engagement with the opening 18, the contact 73 on contact arm 72 will be moved into engagement with the contact 77. This in effect provides a shunt or direct short across the bimetal element which, even though the value is quite low to allow high currents with a minimum voltage drop, has a certain amount of electrical resistance. Thus, a direct short across the bimetal element will drop the current flow through the bimetal element to a miminum so that the element will no longer be effectively heated. When this occurs, the bimetal element begins to cool and tends to return to its normal position, thereby tending to withdraw the locking lever tip 69 from the opening 18. However, the contacts 73 and 74 are so positioned that they will disengage almost at once before there is any substantial movement of the locking lever 68, with the result that the bimetal element will no longer be shorted and current will again pass through the bimetal element to heat it and tend to move the locking lever 68 in the locking direction.
It will be seen that during the spin cycle the shorting effect through the contacts 73 and 77 will tend to have a cycling effect with an oscillating movement with the locking lever 68. However, the magnitude of this movement is quite small and does not have any substantial effect on the position of the locking lever. Thus, when the spin cycle ends, the bimetal will always, regardless of the value of the current, be at substantially the same temperature and position, so that the unlocking time is substantially constant. While the contacts 73 and 77 are thus required to open and close under a relatively small amount of physical movement while the lid lock is actuated, the voltage drop across those contacts is minimal so that there is substantially no arcing effect and the contacts will have a long service life.
It is noted that the bimetal element 44 as shown and described is arranged to have four legs to provide sufficient actuating force. It is recognized that one pair of legs could be eliminated and the bimetal element be in the form of an inverted U with the free legs anchored on the base.
Although the preferred embodiment of this invention has been shown and described, it should be understood that various modifications and rearrangements of the parts may be resorted to without departing from the scope of the invention as disclosed and claimed herein. | A door locking device for an appliance such as a washing machine has a rotatable lock lever actuated to engage a latch carried by the door to hold the door in a closed position. The lock lever is actuated by a bimetallic element which is adapted to be connected in series with the drive motor when the washing machine is in the spin condition so that the electric current passing through the drive motor passes through the bimetallic element and the resulting heating and deflection of the bimetallic element actuates the lock lever. The unit also carries an interlock switch actuated by the latch mechanism to prevent operation when the door is open. A shunt switch is provided to close electrical contacts when the bimetallic element and lock lever are deflected to the locked position to shunt current past the bimetallic member to prevent further heating and to insure a substantially constant unlock time. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application is based on and claims priority of Japanese patent application 2000-398509, filed on Dec. 27, 2000, all of the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor memory device and a method of manufacturing the same, and in particular, to a semiconductor memory device including stacked gate electrodes of which each includes a floating gate electrode and a control gate and a method of manufacturing the same.
2. Description of the Related Art
With development of the information society, a need exists to further increase the integration density of semiconductor memory devices. A flash memory includes a stack of a floating gate and a control gate above a channel region to form a non-volatile memory and hence does not require the refresh operation. Thanks to the advantage that the refresh operation is not required, the flash memory is employed in many electronic apparatuses. For a higher integration density and for a lower operation voltage of the flash memory, it is desired to lower the writing and erasing voltages.
In a flash memory, it is necessary for carriers to tunnel a tunnel oxide film of about 10 nanometer (nm) thickness between a channel and the floating gate. For the tunnel operation, a voltage of about plus or minus 10 volt (V) or more (in magnitude) is required. To lower the writing and erasing voltages, it is effective to minimize the film thickness of the tunnel oxide film.
When the film thickness is lowered to about 3 nm, the voltage necessary for carriers to tunnel the tunnel oxide film can be reduced to about plus or minus 5 V.
However, when the film thickness of the tunnel gate oxide film is minimized, carriers accumulated in the floating gate easily tunnel to extension region of the source/drain region applied with a relatively high voltage. This resultantly reduces the retention time for retaining carriers in the floating gate of the memory device.
A need exists for a semiconductor memory device in which the voltage for operating the device is lowered without reducing the information retention time.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a semiconductor memory device in which the thickness of the tunnel oxide film can be reduced and the deterioration of the retention time can be reduced.
Another object of the present invention is to provide a method of manufacturing a semiconductor memory device of this kind.
According to one aspect of the present invention, there is provided a semiconductor memory device, comprising a semiconductor substrate including an active region of first conductive type; a gate insulating layer formed on said active region, said gate insulating layer including a thin central section and thick end section on each side thereof; a floating gate electrode formed on said gate insulating layer;
an inter-electrode insulating layer formed on said floating gate electrode; a control gate electrode formed on said inter-electrode insulating layer; a pair of source/drain regions of second conductive type respectively extending in said active region from respective sides of said floating gate electrode respectively below said thick end sections, said source/drain regions being apart from said thick end section.
According to one aspect of the present invention, there is provided a method of manufacturing a semiconductor memory device, comprising the steps of: (a) forming a stack of a first gate insulating layer, a floating gate electrode layer, an inter-electrode insulating layer, and a control electrode layer on a semiconductor substrate including an active region of first conductivity type; (b) patterning said stack using a mask and thereby creating a gate electrode pattern; (c) causing a chemical reaction for said gate electrode pattern from both sides thereof and forming thereby a second gate insulating layer on each side of a central section of said first gate insulating layer, said second gate insulating layer being thicker than said first gate insulating layer; and (d) implanting ions of impurity of a second conductivity type in said active regions on both sides of said gate electrode pattern and forming thereby first source/drain regions respectively extending below said second insulating layers.
Since the thickness of the gate insulating film is increased in the vicinity of the source/drain region, the amount of a tunneling leakage current from the floating gate electrode to the source/drain region is reduced.
This improves the information retaining capability of the semiconductor memory device
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the present invention will become more apparent from the consideration of the following detailed description taken in conjunction with the accompanying drawings in which:
FIGS. 1A and 1B are plan views of a semiconductor memory device in an embodiment of the present invention, and FIGS. 1C and 1D are an equivalent circuit diagram and a cross-sectional view thereof;
FIGS. 2A to 2 C are equivalent circuits for explaining operation of the semiconductor memory device shown in FIGS. 1A to 1 D;
FIGS. 3A to 3 F are cross-sectional views of a semiconductor substrate for explaining processes of manufacturing the semiconductor memory device in the embodiment;
FIGS. 4A to 4 F are cross-sectional views of a semiconductor substrate for explaining processes of manufacturing a semiconductor memory device in another embodiment of the present invention; and
FIGS. 5A to 5 E are cross-sectional views of a semiconductor substrate for explaining processes of manufacturing a semiconductor memory device in still another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Description will now be given of an embodiment of the present invention by referring to the drawings. FIGS. 1A and 1B are plan views of a semiconductor memory device in an embodiment of the present invention and FIGS. 1C and 1D are an equivalent circuit diagram and a cross-sectional view thereof, respectively.
As shown in FIG. 1A, a silicon chip SC includes a plurality of memory cell arrays MCA; a plurality of regions BSD/SA each of which includes a bit line decoder, a source line decoder, and a sense amplifier circuit; a word line decoder WD, a high-voltage generator circuit HV, and an input/output circuit I/O. Each memory cell array includes a plurality of memory cells arranged in a matrix.
FIG. 1B shows a layout example of the memory cell array. A device isolation zone ISO defines a plurality of active regions AR, and a word line WL is disposed to intersect a central section of each active region AR.
FIG. 1C is an equivalent circuit diagram showing part of the configuration of the memory cell array. The memory cells MC are arranged in a matrix form, and a gate electrode of each memory cell MC is connected to an associated word line WL 1 or WL 2 . A source region of each memory cell MC is connected to a source line SL 1 . A drain region of each memory cell MC is connected to an associated bit line BL 1 or BL 2 .
Operation of each memory cell MC is controlled by potential of the associated word line WL connected to its gate electrode, potential of the associated source line SL connected to its source region, and potential of the associated bit line BL connected to its drain region. In the erase and write operations, a relatively high voltage is applied between or is developed across the gate electrode and the channel region.
FIG. 1D is a cross-sectional view showing construction of each memory, cell MC. On a surface of a silicon substrate 1 including a p-type region, a thin tunnel oxide film 2 and thick tunnel oxide films 3 on both sides thereof are formed, which collectively constitute a gate insulation film. Formed on the gate insulation film 2 , 3 is a floating gate electrode 4 on which a control gate electrode 6 is formed with an inter-electrode insulating film 5 interposed therebetween. The control gate electrode 6 , the inter-electrode insulating film 5 , the floating gate electrode 4 , and the gate insulating film 2 , 3 configure insulated gate electrode structure.
Formed on sidewalls of the insulated gate electrode structure are sidewall insulating spacers SW. Extension regions 7 S and 7 D respectively of the source and drain regions are formed to be self-aligned to the insulated gate electrode structure, and source/drain contact regions 9 S and 9 D are formed to be self-aligned to outer sidewalls respectively of the sidewall insulating spacers SW.
Since the floating gate electrode 4 is isolated from the source and drain extension regions 7 S and 7 D by the thick tunnel insulating film 3 , the tunnel leakage current is prevented and the memory state of the floating gate electrode 4 can be kept retained for a long period of time. In the central section of the floating gate electrode 4 , since the thin tunnel insulating film 2 is disposed between the floating gate electrode 4 and the channel region, the write and erase operations can be achieved with a low driving voltage.
FIGS. 2A to 2 C are equivalent circuit diagrams for explaining operation of the semiconductor memory device shown in FIGS. 1A to 1 D. FIG. 2A shows driving voltages for the write operation. In this case, information is written in a selected memory cell (SMC). A voltage of 5 V is applied to the word line WL 1 and the source line SL. The bit line BL 1 is kept at 0 V. Electrons induced in the channel tunnel or pass through the tunnel insulating film and enter the floating gate electrode.
In this regard, the bit lines, e.g., the bit line BL 2 not used for the write operation are kept at 5 V such that electrons are not induced in the channel to thereby prevent the tunneling of electrons into the floating gate region. The word lines, e.g., the word line WL 2 associated with the non-selected memory cells in a selected column, which includes the cell to be subjected to the write operation, are kept at 0 V such that electrons do not enter the floating gate region.
FIG. 2B shows an example of driving voltages for reading the contents of the memory cell for which the write operation has been achieved. The word line WL 1 is set to 1.5 V and the source line SL 1 is set to 0 V. A voltage of 1.5 V is then applied to the bit line BL 1 . If electrons are not beforehand stored in the floating gate, a channel is induced below the gate electrode to which 1.5 V is applied, and hence electrons flow from the source to the drain. If electrons are beforehand stored in the floating gate, a channel is not induced below the gate electrode even when a voltage of 1.5 V is applied to the control gate, and the selected memory cell SMC is kept in the off state.
For non-selected memory cells in the row connected to the word line WL 1 on which 1.5 V is applied to, the bit lines such as the bit line BL 2 are kept at 0 V to prevent an electric current between the source and the drain. In the memory cells MC connected to the rows other than the row including the selected memory cell SMC, the gate electrode is kept at 0 V. This does not induce a channel in the memory cell and hence the memory cell is kept in the off state.
FIG. 2C shows an erase operation. In this operation, all memory cells belonging to the same row are erased. A voltage of −5 V is applied to the word line WL 1 and a voltage of 0 V is applied to the source line SL 1 and the bit lines BL 1 , BL 2 , etc. In each memory cell in which−5 V is applied to its control gate and its source and drain are kept at 0 V, electrons stored in the floating gate are repelled by a negative voltage of the control gate. The electrons therefore tunnel into the channel region. In the rows for which the erase operation is not to be conducted, the word lines such as WL 2 are kept at 0 V and hence the electrons in the floating gates are kept retained.
Referring next to FIGS. 3A to 3 F, 4 A to 4 F, and 5 A to 5 E, description will be given in more detail of a method of manufacturing a semiconductor memory device similar to that shown in FIG. 1 D.
FIGS. 3A to 3 F are cross-sectional views showing a method of manufacturing a semiconductor memory device in an embodiment of the present invention.
As shown in FIG. 3A, on a surface of a silicon substrate 11 including a p-type active region, a silicon oxynitride film 12 , an n + -type polycrystalline silicon layer 14 , a silicon oxide layer 15 , and an an n + -type polycrystalline silicon layer 16 are stacked. The silicon oxynitride layer 12 is formed, for example, as follows. The p-type silicon substrate is heated up to about 800° C. in a dry oxidizing atmosphere to form a thermal oxide film of about 3 nm thickness. In an atmosphere of nitrogen oxide (NO), the substrate is then annealed at about 800° C. The n + -type polycrystalline silicon layer 14 with a thickness of about 100 nm is formed by chemical vapor deposition (CVD). The film is doped to an n + -type film by doping impurity in the process of CVD. Alternatively, after a polycrystalline silicon film is formed without impurity, the film is doped to an n + -type film by ion implantation.
A silicon oxide layer 15 of about 10 nm thick is formed on a surface of the n + -type polycrystalline silicon layer 14 by thermal oxidation or CVD. On the silicon oxide layer 15 , an n + -type polycrystalline silicon film 16 of about 100 nm thickness is formed by CVD. Impurity can be implanted in either ways as follows. During the film forming process, the film is doped at the same time. Or, after a non-doped polycrystalline silicon film is formed, the film is doped by ion implantation.
As shown in FIG. 3B, a photo-resist mask M is patterned on the polycrystalline silicon film 16 . Using the resist mask M as an etching mask, stacked structure is patterned. The patterning is carried out for the polycrystalline silicon film 16 , the silicon oxide film 15 , polycrystalline silicon film 14 , and the gate electrode film 12 using the mask M. Thereafter, the mask M is removed.
As shown in FIG. 3C, using the stacked structure as a mask, n-type impurity is implanted into the p-type region of the silicon substrate 11 to form source/drain regions 17 .
In a case in which an ion implantation process is also conducted after the formation of the sidewall insulating spacers, the source/drain regions become source/drain extension regions.
As shown in FIG. 3D, after the ion implantation, an oxide film 18 of about 5 nm is formed on the silicon surface by thermal oxidation. At the interface between the silicon oxynitride layer 12 and the polycrystalline silicone film 14 , the oxidation speed of the polycrystalline silicon is high. Therefore, a silicon oxide layer 13 grows in each side portion of the polycrystalline film 14 contacting the oxynitride layer 12 toward a central section thereof. That is, on each side portion of the polycrystalline silicon film 14 which serves as a floating gate, a silicon oxide layer 13 is formed on the oxynitride silicon layer 12 . This elongates the distance between the floating gate and the channel region.
The thermal oxidation process is conducted such that the upper surfaces of the source/drain regions (extension regions) 17 are completely covered with the silicon oxide layer 13 . Therefore, a gate insulating film formed by the stacked structure of the silicon oxynitride layer 12 and the silicon oxide layer 13 is interposed between each extension region and the floating gate region. This increases the overall thickness of the insulating film and hence prevents the leakage current.
As shown in FIG. 3E, a silicon oxide layer is deposited by CVD and then a certain thickness of the silicon oxide layer is etched by anisotropic etching, to remove the oxide layer on the planar area. On the sidewalls of the stacked gate structure, the sidewall insulating spacers SW remain. Using the stacked gate structure and the sidewall insulating spacers SW as a mask, an ion implantation process is conducted to form source/drain (contact) regions 19 having a large junction depth. Thereafter, an interlevel insulating film is formed, and contact holes are opened to expose the contact areas. A gate electrode G, a source electrode S, and a drain electrode D are formed in the contact holes.
In the description, the source/drain regions have the extension regions. However, there may also be used single drain structure. In this case, the ion implantation shown in FIG. 3C is conducted at a relatively high density. After the process of FIG. 3D is finished, an interlevel insulating film is formed.
FIG. 3F shows constitution of a memory cell in the single drain structure. The source/drain regions are constructed with n + -type silicon regions 17 x formed by one ion plantation process. The sidewall insulating spacers are not formed. The stacked gate electrode is buried in the interlevel insulating layer 20 . The source electrode S, the gate electrode G, and the drain electrode D are connected to the source region, the control gate region, and the drain region, respectively.
In the above configuration, the gate insulating film is formed of a silicon oxynitride layer, and a polycrystalline silicon layer is formed thereon. Resultantly, thermal oxidation is enhanced in a horizontal direction in the polycrystalline silicon layer at the interface between the gate insulating film and the polycrystalline silicon layer. A similar advantage can also be expected when the gate insulating film is formed of a silicon nitride film. In this case, it is enough if the gate insulating film 12 of FIG. 3A is formed of a silicon nitride film.
FIGS. 4A to 4 F are schematic cross-sectional views to explain processes of manufacturing a semiconductor memory device in another embodiment of the present invention. After isolation regions are formed on a surface of a silicon substrate 21 , a gate insulating film 22 , a polycrystalline silicon film 24 , an inter-electrode insulating film 25 , and a polycrystalline silicon film 26 are formed. This is substantially the same in structure as that shown in FIG. 3 A and can be formed in substantially the same process.
As shown in FIG. 4B, a resist mask M is formed on the polycrystalline silicon film 26 . The stacked gate electrode structure is patterned by dry etching process using bromine-containing etchant under a relatively high gas pressure. It is to be understood that the etchant is changed when the inter-electrode insulating film 25 of silicon oxide is to be etched.
After the polycrystalline silicon film 24 for a floating gate is etched, notches N are formed in the polycrystalline silicon film 24 on the side of the gate insulating film 22 by over-etching. After the notches N are formed, the gate insulating film 22 of silicon oxide remaining on the surface of the silicon substrate is etched in a wet etching process using diluted hydrogen fluoride (HF), as shown in FIG. 4 C.
As shown in FIG. 4D, an insulating film for the sidewall insulating spacers SW is formed by CVD such that the notches N are filled with the insulating film. Thereafter, a certain thickness of the insulating film is etched by anisotropic dry etching to remove the insulating film on the planar surface areas. In this way, the sidewall insulating spacers SW are formed. In each notch N, an insulating region 23 is formed of the material of the sidewall insulating spacers SW.
The sidewall insulating spacers SW and the embedding insulating regions 23 are formed, for example, of silicon oxide.
The sidewall insulating spacers SW and the buried insulating regions 23 may also be formed of a silicon oxynitride layer. In this case, since silicon oxynitride has a higher dielectric contact than silicon oxide, although a thick gate insulating film exists on each side of the floating gate, effect of the gate voltage is enhanced. Therefore, the thick gate insulating film can function like a thin gate oxide film.
The notches may be formed in another method. FIG. 4E shows a gate electrode in which a metal nitride layer 24 a of titanium nitride (TiN) or a tantalum nitride (TaN) is deposited on the gate insulating film 22 , and a gate electrode layer 24 b of polycrystalline silicon or the like is deposited on the metal nitride layer 24 a . In this gate electrode structure, the lower gate electrode layer 24 a can be selectively etched with respect to the upper gate electrode layer 24 b.
For example, after the stacked gate electrode structure is patterned using a photo resist mask as shown in FIG. 4B, when a sulfuric acid—hydrogen peroxide etching process is conducted, the lower gate electrode layer 24 a of, e.g., titanium nitride (TiN) or tantalum nitride (TaN) is etched from its side surfaces. Resultantly, notches N are formed as shown in FIG. 4 F. The gate oxide film 22 below the notches N may be removed or may be kept remained. In a subsequent process of FIG. 4D, an insulating film is filled in the notches N, and sidewall insulating spacers can be formed.
FIGS. 5A to 5 E are cross-sectional views of a semiconductor substrate schematically showing processes of manufacturing a semiconductor memory device in another embodiment of the present invention.
As shown in FIG. 5A, on a silicon substrate 31 , a silicon oxide film 32 , a polycrystalline, silicon-germanium (SiGe) mixed crystal layer 33 , an n + -type polycrystalline silicon layer 34 , an inter-electrode insulating silicon oxide layer 35 , and an n + -type polycrystalline silicon layer 36 are formed. The silicon oxide layer 32 is formed, for example, to have a thickness of about 3 nm by thermal oxidation. The silicon-germanium mixed crystal layer 33 is formed to have a thickness of about 10 nm, for example, by CVD. The polycrystalline silicon layers 34 and 36 and the inter-electrode insulating silicon oxide layer 35 are formed in almost the same way as for the foregoing embodiments.
As shown in FIG. 5B, the polycrystalline silicon layer 36 , the inter-electrode insulating silicon oxide layer 35 , the polycrystalline silicon layer 34 , the silicon-germanium mixed crystal layer 33 , and the silicon oxide layer 32 are patterned using a resist mask M.
As shown in FIG. 5C, using the stacked gate electrode as a mask, n-type impurity ions are implanted onto the silicon substrate 31 to form source/drain regions 37 .
As shown in FIG. 5D, an oxide film of about 5 nm thickness is formed on a surface of the silicon substrate 31 by thermal oxidation. In the thermal oxidation, silicon-germanium (SiGe) mixed crystal has a higher oxidation rate than silicon (Si). Therefore, the silicon-germanium (SiGe) mixed crystal layer 33 is oxidized to a deeper position from both sides thereof below the polycrystalline silicon layer 34 which serves as a floating gate. Resultantly, an oxide layer of silicon-germanium or a silicon oxide layer 33 x including germanium is formed. Below the polycrystalline silicon layer 34 , the Si—Ge mixed crystal layer 33 remains in its central section.
As shown in FIG. 5E, after the sidewall insulating spacers SW are formed, source/drain regions 39 having a deeper junction than the extensions 37 are formed according to necessity. Below both side sections of the floating gate, a silicon oxide layer containing germanium of about 10 nm thickness is formed on a thin silicon oxide layer. This advantageously prevents the leakage current.
While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by those embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention. | A non-volatile semiconductor memory comprising a semiconductor substrate, a gate insulating film formed on the substrate, and having a thin central section and thick end sections, a floating gate formed on the rate insulating film, an inter-electrode insulating film formed on the floating gate, a control gate formed on the inter-electrode insulating film, and source/drain regions formed in the substrate on both sides of the floating sate and having extensions extending under the thick end sections of the floating gate, and separated from the thin central section of the gate insulating film, wherein the thin central section enables tunneling of carriers at a low applied voltage, and thick end sections prevent tunneling of stored charges to the extensions and enhance retention of the stored charges. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an improved water precipitator which inexpensively provides precipitated water over an extended surface area of land in a high temperature region.
2. Description of the Prior Art
In the past, high temperature regions throughout the world have suffered from many problems due to water shortages in that region. Efforts have been made to solve this problem, however most solutions have proved to be too costly for efficient use in the production of drinking water or water for agricultural use. Water production systems tend to require large expenditures of energy and produce relatively small quantities of water. Also, many of the solutions provide a reservoir of water, which then requires that the water be transported to the area for desired use. In agricultural uses, the requirement of transport of the water makes water production under these systems cost prohibitive.
Nasser et al (U.S. Pat. No. 4,182,132) discloses a system which may be used to produce water. Nasser primarily discloses an apparatus for cooling ambient air temperatures in humid, high-temperature regions. A by-product of the cooling apparatus is condensed water. The Nasser apparatus is a tower which utilizes a blower to draw in ambient air to the center of the tower. The cooler air then sinks or is drawn downward through an evaporator in the system. Part of the air is also forced upwardly through the condenser of the system. Water then condenses on the cold surface of the evaporator and is collected at the bottom of the tower. However, Nasser uses a refrigeration cycle requiring a condenser, an evaporator and a compressor. Nasser also requires a motor-powered blower to draw air into the device. Therefore, the Nasser apparatus would require too large of expenditures of energy for use in the production of large quantities of water for extended surface areas of land.
Because of the primary purpose of Nasser, to cool the ambient air, the air must be collected at an intermediate location well above ground level and above the cooler layer along the ground,. The water collects at the base of the tower and must be transported to where it is needed. Therefore, it would be every inefficient to use the Nasser apparatus to provide water throughout an extended surface area.
Therefore, a need still existed for a water precipitator which inexpensively produces water throughout an extended surface area of land in a high temperature region without a need for a separate transport system.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved water precipitator apparatus which inexpensively produces water.
It is a further object of this invention to provide an improved water precipitator apparatus which precipitates water throughout an extended surface area of land.
It is a still further object of this invention to provide an improved water precipitator apparatus which may be used in regions of high temperature and various levels of humidity.
The aforementioned and other objects are accomplished, according to the present invention, by an improved water precipitator which collects hot air over an extended surface land area, forces the air against a system of piping with refrigerant running throughout, then collects the resulting precipitated water.
The foregoing and other objects, features and advantages of this invention will be apparent from the following, more particular, description of the preferred embodiments of this invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the improved water precipitator apparatus with elements shown separately.
FIG. 2 is a perspective view of the invention.
FIG. 3 is a side cross sectional taken along line 2--2 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 of the accompanying drawings which set forth the present invention in greater detail and in which like numerals designate like features, an improved water precipitator apparatus 10 is generally comprised of a roof member 14, a plurality of piping 30, a plurality of storage tanks 32, a structural member 34, a plurality of air intake means 20, and a plurality of wall members 12. In the preferred embodiment, the structural member 34 is a cross-shaped member, approximately eight feet high with four arms 26 extending approximately twelve feet in length. This size and shape of structural member 34 has proven to most efficiently precipitate water over an extended surface area of land with a minimal requirement of wind flow in any direction. The shape or size of the structural member, however, can be altered to conform to specific needs and terrain conditions.
The wall members 12 are constructed out of stone and seal the ends of the arms 26 of the structural member 34 to prevent air from entering the structural member 34 through the ends of the arms 26. Therefore, the preferred embodiment comprises four wall members 12, one for each arm 26. The air intake means 20 are comprised of a series of air intake flaps 21. layered down the height of the arms 26 of the structural member 34. Each air intake flap 21 is hinged on both sides to the structural member 34. The air intake flaps 21 overlap at an angle sufficient to allow a five mile per hour wind to activate the air intake means 20. Therefore, a minimum five mile per hour wind will either force the air intake flaps 21 into an open or closed position depending on the direction of the wind.
The plurality of piping 30 is located on top of the structural member 34. The piping 30 provides a pathway through which the refrigerant flows. The piping 30 is preferably copper to provide the best conductivity. In the preferred embodiment, the piping 30 is coiled and stacked to cover the entire cross-sectional area of the structural member 34. The more piping 30 used, the more precipitation will occur. Therefore, the amount of pipe 30 can be altered to provide the desired amount of precipitated water. Each end of the piping 30 is connected to a storage tank 32 through a control valve 18. One storage tank 32 is of a sufficiently larger volume than the storage tank 32 connected to the opposite end of the piping 30. Therefore, when the control valves 18 are opened, the refrigerant will naturally flow from the storage tank 32 with a larger volume to the storage tank 32 of a smaller volume. The refrigerant circulated in the piping 30 is preferably butane, however other types of refrigerant may be used, including compressed freon.
The roof member 14 covers the piping 30, and contacts the upper surface of the structural member 34. The roof member 14 contains an air outlet means 16 for allowing the hot air to rise out of the structural member 34. In the preferred embodiment, the air outlet means 16 is a plurality of elongated slots in the roof member 14.
As best shown in FIG. 2, the structural member 34 may be supported by a plurality of cinder blocks 22. The cinder blocks 22 are located along the arms 26 of the structural member 34 on the outer side of the air intake means 20. The cinder blocks 22 provide more support for the structural member 34 and protect the air intake means 20 from damage.
As best shown in FIG. 3, the cinder blocks 22 contain a plurality of apertures 28 to allow air flow through the cinder blocks 22 to activate the air intake flaps 21. The cinder blocks 22 and the structural member 34 are situated upon a water collection means 24 for collecting the precipitated water. The water collection means 24 is preferably constructed of a fiberglass material. The water collection means 24 may also be built at an angle so that the precipitated water runs to a specified collection point.
SYSTEM OPERATION
The water precipitator 10 is prepared for use by connecting the larger storage tank 32 at one end of the piping 30 and the smaller storage tank 32 at the other end of the piping 30. The control valves 18 are then opened so that the refrigerant in the storage tanks 32 freely flows slowly through the piping 30.
For example, a minimum wind of five miles per hour blowing through the cylinder blocks 22 (See FIGS. 2 and 3) on one side will pass through the air intake flaps 21 adjacent to the side of the cinder blocks 22, but will shut the air intake means 20 on the opposite side of the structure by closing the louvres 20 on the opposite side thereby trapping the hot air inside the structural member 34. The wall members 21 also function to trap the hot air inside the structural member 34. The hot air naturally rises and comes into contact with the piping 30 filled with flowing refrigerant. As a result of the hot air touching the cold piping 30, which lowers the temperature of the air below the dew point, water precipitates on the piping and drips downward into the water collection means 24 at the bottom of the structural member 34. The hot air then escapes by rising from the structural member 34 through the air outlet means 16 in the roof member 14 of the water precipitator apparatus 10.
While the invention has been particularly shown and described in reference to the preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made without departing from the spirit and scope of the invention. | An improved water precipitator which provides a water supply over an extended surface area of land in a high temperature region by condensing water on piping chilled by a refrigerant circulating within the piping. | 4 |
TECHNICAL FIELD
This invention relates to the general field of sensors and more specifically to sensors for measuring damaging environmental conditions of structures such as corrosion, coatings breakdowns, and fatigue.
BACKGROUND
A major goal in environmental testing has long been to create a sensor that could be utilized in field or service conditions to detect corrosion and adhesion on metal structures of any size before significant degradation has occurred.
One example is the aging fleets of aircraft in use both in the military and commercial sectors, where corrosion of body and support component surfaces in secluded areas is of crucial concern. Current efforts to detect corrosion on aircraft surfaces consist of visual inspection of the accessible surfaces on a routine basis. Aircraft surfaces that are difficult to access often receive less attention and may not be inspected until aircraft overhaul, which typically occurs every five years. The overhaul process involves the disassembly of the body of the aircraft. The body panels are removed and inspected leaving only a frame skeleton. This process has often revealed corrosion problems in many of the remote areas of the dismantled aircraft. Potential safety concerns prompt the need for continuous corrosion detection capabilities in secluded aircraft compartments.
Evaluation of materials and coatings and the determination or prediction of corrosion performance of both painted and uncoated metal structures or specimens under ambient field or service conditions has traditionally involved visual comparisons which are subjective and require blistering, rusting, or other advanced stages of degradation. The use of laboratory techniques, such as electrochemical impedance spectroscopy (EIS- or AC impedance) has been used to understand and predict corrosion performance during immersion exposures in different electrolytes was limited to small structures or witness specimens that could be immersed, small sections of material cut from large structures, or attachment to the structure of a clamp-on liquid cell in which a liquid or semi-liquid electrolyte and remote counter and reference electrodes were contained.
The immersion of small specimens requires either the destructive sampling of a large structure or the use of witness specimens prepared differently than the actual structure of interest (although the witness specimens and the structure may be prepared at the same time, inherent differences in coating small and large surfaces and inadvertent differences caused by operator error will prevent the witness specimens from being exactly the same as the structure). Additionally, witness specimens will be exposed to slightly different environmental conditions compared to a large structure. Furthermore, the immersion in an electrolyte is not necessarily the exposure condition relevant to the structure being inspected.
Inspection of a large structure using conventional EIS methodologies required complete immersion or use of a clamp-on cell. Such cells would be filled with a liquid or semi-liquid electrolyte (e.g., Kihira et al, U.S. Pat. No. 4,806,849) or a spongy medium impregnated with a liquid electrolyte (e.g., Kondou et al, U.S. Pat. No. 5,221,893) with remote electrodes immersed in the electrolyte or in intimate contact with the electrolyte-impregnated sponge. These cells required an accessible, flat, smooth, and horizontal area. The set-up was considered to be time consuming and had to be performed for each measurement. Corrosion was detected only directly under the cell and use of the cell actually caused artifactual damage to the coating in many instances because of exposure to the electrolyte during measurement.
Davis et al, U.S. Pat. No. 5,859,537, developed a painted electrode sensor which eliminates many of the problems discussed above. The actual structure is being inspected without exposure to an extrinsic electrolyte. Measurements are possible under most natural or accelerated conditions and material and coating degradation are detectable from the very early stages. However, the Davis et al, sensor requires an electrode to be permanently painted onto the structure and is time-consuming for all the fabrication steps to be completed. It is not suitable for structures in which appearance or aerodynamics precludes an attached sensor. The sensor can induce artifactual damage in a small class of materials, primarily porous coatings.
Further prior art approaches include galvanic sensors that combine two different materials and sense electric current flows between the two.
In another prior art application linear polarization resistance (LPR) has been used. In the LPR technique, a potential (typically of the order of 10-20 mV) is applied to a sensor element and the resulting (“linear”) current response is measured. This small potential perturbation is usually applied step-wise, starting below the free corrosion potential and terminating above the free corrosion potential. The polarization resistance is the ratio of the applied potential and the resulting current response. This “resistance” is inversely related to the uniform corrosion rate.
Douglas (U.S. Pat. No. 6,843,135) describes an application of using magnetic detectors to monitor corrosion inside of enclosed containers using sacrificial coupons. This approach makes use of spring-loaded coupons that are designed to fail when a specified level of corrosion occurs. A permanent magnet located on the corrosion coupon is used to transmit the failure of the coupon outside of the container. While this approach has potential to provide a contact less monitoring technique, a more continuous monitoring that would indicate a developing problem is much more desirable.
Magnetic Sensors. One sensor field of high potential is more modern magnetic sensors. These include, among others, eddy current, Hall effect, and giant magneto resistor sensors These detect changes, or disturbances, in magnetic fields that have been created or modified, and from them derive information on properties such as direction, presence, rotation, angle, or electrical currents. The output signal of these sensors requires some signal processing for translation into the desired parameter. Although magnetic detectors have been considered somewhat more difficult to use, they potentially provide more accurate and reliable data—without physical contact.
In eddy current inspection, the eddy currents are generated in the test material due to mutual induction. The test probe is basically a coil of wire through which alternating current is passed. When alternating current is passed through the coil, a magnetic field is generated in and around the coil. When the probe is brought in close proximity to a conductive material, such as aluminum, the probe's changing magnetic field generates current flow in the material. The induced current flows in closed loops in planes perpendicular to the magnetic flux. They are named eddy currents because they are thought to resemble the eddy currents that can be seen swirling in streams.
Eddy currents produce their own magnetic fields that interact with the primary magnetic field of the coil. By measuring changes in the resistance and inductive reactance of the coil, information can be gathered about the test material. This information includes the electrical conductivity and magnetic permeability of the material, the amount of material cutting through the coils magnetic field, and the condition of the material (i.e. whether it contains cracks or other defects.) The distance that the coil is from the conductive material is called liftoff, and this distance affects the mutual-inductance of the circuits. Liftoff can be used to make measurements of the thickness of nonconductive coatings, such as paint, that hold the probe a certain distance from the surface of the conductive material.
There are several sensors that use the Lorentz force, or Hall effect, on charge carriers in a semiconductor. The Lorentz force equation describes the force F L experienced by a charged particle with charge q moving with velocity v in a magnetic field B:
F L =q ( v×B )
Since F L , v, and B are vector quantities, they have both magnitude and direction. The Lorentz force is proportional to the cross product between the vectors representing velocity and magnetic field; it is therefore perpendicular to both of them and, for a positively charged carrier, has the direction of advance of a right-handed screw rotated from the direction of v toward the direction of B. The acceleration caused by the Lorentz force is always perpendicular to the velocity of the charged particle; therefore, in the absence of any other forces, a charge carrier follows a curved path in a magnetic field.
Hall Effect Sensors. The Hall effect is a consequence of the Lorentz force in semiconductor materials. When a voltage is applied from one end of a slab of semiconductor material to the other, charge carriers begin to flow. If at the same time a magnetic field is applied perpendicular to the slab, the current carriers are deflected to the side by the Lorentz force. Charge builds up along the side until the resulting electrical field produces a force on the charged particle sufficient to counteract the Lorentz force. This voltage across the slab perpendicular to the applied voltage is called the Hall voltage.
Magnetoresistors. The simplest Lorentz force devices are magneto resistors that use semiconductors such as InSb and InAs with high room-temperature carrier mobility. If a voltage is applied along the length of a thin slab of semiconductor material, a current will flow and a resistance can be measured. When a magnetic field is applied perpendicular to the slab, the Lorentz force will deflect the charge carriers. If the width of the slab is greater than the length, the charge carriers will cross the slab without a significant number of them collecting along the sides. The effect of the magnetic field is to increase the length of their path and, thus, the resistance. An increase in resistance of several hundred percent is possible in large fields. To produce sensors with hundreds to thousands of ohms of resistance, long, narrow semiconductor stripes a few micrometers wide are produced using photolithography. The required length-to-width ratio is accomplished by forming periodic low-resistance metal shorting bars across the traces. Each shorting bar produces an equipotential across the semiconductor stripe. The result is, in effect, a number of small semiconductor elements with the proper length-to-width ratio connected in series.
Magnetoresistors formed from InSb are relatively insensitive in low fields; in high fields, however, they exhibit a resistance that changes approximately as the square of the field. They are sensitive only to that component of the magnetic field perpendicular to the slab and not to whether the field is positive or negative. Their large temperature coefficients of resistivity are caused by the change in mobility of the charge carriers with temperature. The sensors are made with either single resistors or pairs of spaced resistors. The latter are used to measure field gradients and are sometimes combined with external resistors to form a Wheatstone bridge. A permanent magnet is often incorporated in the field gradient sensor to bias the magnetoresistors up to a more sensitive part of their characteristic curve.
Integrated Hall sensors. Hall devices are often combined with semiconductor elements to create integrated sensors. Adding comparators and output devices to a Hall element, for example, yields unipolar and bipolar digital switches. Adding an amplifier increases the relatively low voltage signals from a Hall device to produce ratiometric linear Hall sensors with an output centered on one-half the supply voltage. Power usage can even be reduced to extremely low levels by using a low duty cycle.
Giant Magnetoresistive (GMR) Devices. Large magnetic field dependent changes in resistance are possible in thin film ferromagnet/nonmagnetic metallic multilayers. Changes in resistance with magnetic field of up to 70% have been seen. Compared to the small percent change in resistance observed in anisotropic magnetoresistance, this phenomenon was truly giant magnetoresistance.
The resistance of two thin ferromagnetic layers separated by a thin nonmagnetic conducting layer can be altered by changing the moments of the ferromagnetic layers from parallel to antiparallel, or parallel but in the opposite direction.
GMR materials for magnetic field sensors are sometimes used in Wheatstone bridge configurations, although simple GMR resistors and GMR half bridges can also be fabricated. A sensitive bridge can be made from four photolithographically patterned GMR resistors, two of which are active elements. These resistors can be as narrow as 2 μm, allowing a serpentine 10 k resistor to be patterned in an area as small as 100 μm 2 . The vary narrow width also makes the resistors sensitive only to the magnetic field component along their long dimension. Small magnetic shields are plated over two of the four equal resistors in a Wheatstone bridge, protecting them from the applied field and allowing them to act as reference resistors. Since they are fabricated from the same material, they have the same temperature coefficient as the active resistors. The two remaining GMR resistors are both exposed to the external field. The bridge output is therefore twice the output from a bridge with only one active resistor. The bridge output for a 10% change in these resistors is ˜5% of the voltage applied to the bridge.
Smart sensors with sensing elements and associated electronics such as amplification and signal conditioning on the same die are the latest trend. GMR materials are sputtered onto wafers and can therefore be directly integrated with semiconductor processes. The small sensing elements fit well with the other semiconductor structures and are applied after most of the semiconductor fabrication operations are complete. Because of the topography introduced by the many layers of polysilicon, metal, and oxides over the transistors, areas must be reserved with no underlying transistors or connections. These areas will have the GMR resistors. The GMR materials are actually deposited over the entire wafer, but the etched sensor elements remain only on these reserved, smooth areas on the wafers.
Among the functions built into an integrated sensor are regulated voltage or current supplies to the sensor elements; threshold detection to provide a switched output when a preset field is reached; amplifiers; logic functions, including divide-by-2 circuits; and various options for outputs. With these elements, a 2-wire sensor can be designed that has two current levels—low when the field is below a threshold and high when the field is above the threshold.
Onboard sensor electronics can increase signal levels to significant voltages with the least pickup of interference. It is always best to amplify low-level signals close to where they are generated. Converting analog signals to digital (switched) outputs within the sensor is another way to minimize electronic noise. The use of comparators and digital outputs makes the nonlinearity in the output of sandwich GMR materials of less concern. Even the hysteresis in such materials can be useful, since some hysteresis is usually built into comparators to avoid multiple triggering of the output due to noise.
GMR materials have been successfully integrated with both BiCMOS and bipolar semiconductor underlayers. The wafers are processed with all but the final layer of connections complete. GMR material is deposited on the surface and patterned. The next step is the application of a passivation layer through which windows are cut to permit contact to both the upper metal layer in the semiconductor wafer and to the GMR resistors. The final layer of metal is then deposited and patterned to interconnect the GMR sensor elements and to connect them to the semiconductor underlayers. This layer also forms the pads to which wires will be bonded during packaging. A final passivation layer is deposited, magnetic shields and flux concentrators are plated and patterned, and windows are etched through to the pads.
The potential accuracy and reliability of magnetic sensors, coupled with their contact-less aspect, make them potential candidates for environmental damage sensors. Although it is known that the magnetic activity of a corroding sample can be used for non-destructive and real-time quantification of electrochemical corrosion activity, defined practical systems for making use of this characteristic have not been disclosed. What is needed are new magnetic sensor systems that take advantage of these characteristics in the unique application of remote, unmanned long term environmental monitoring of structures.
What is needed therefore is an apparatus and method for continuously measuring environmental degradation in the environment of a structure that provides the accuracy and reliability of magnetic measurement technology. Providing this is an aspect of the instant invention.
SUMMARY
The needs discussed are addressed by the instant invention.
One aspect of the invention is a sensor apparatus for measuring environmental degradation in the environment of a structure including at least: a first magnetic field sensor element with associated electronics mounted in a fixed position in a sensor housing, the sensor housing mounted in close proximity to the structure; a first sacrificial material coupon mounted in a fixed position in the immediate vicinity of the magnetic field sensor element, the first sacrificial material coupon being chosen to represent the material of the structure and being mounted so as to be exposed to the environment of the structure; wherein the associated electronics is effective to capture and record magnetic field strength or magnetic fluxes over time as measured by the first magnetic field sensor element.
Another aspect of the invention is a sensor apparatus for measuring environmental degradation in the environment of a structure including at least: a first magnetic field sensor element with associated electronics mounted in a fixed position in a sensor housing, the sensor housing mounted in close proximity to the structure; a first sacrificial material coupon mounted in a fixed position in the immediate vicinity of the magnetic field sensor element, the first sacrificial material coupon being chosen to represent the material of the structure and being mounted so as to be exposed to the environment of the structure; a second sacrificial material coupon with associated electronics mounted in a fixed position in the immediate vicinity of a second magnetic field sensor element, the second material coupon mounted so as to not be exposed to the environment of the structure; wherein the second sacrificial material coupon is of the same material of the first sacrificial material coupon; wherein the associated electronics is effective to capture and record magnetic field strength or magnetic flux differences between said first and second magnetic sensor elements over time.
Another aspect of the invention is a sensor apparatus for measuring environmental degradation in the environment of a structure including at least: a first magnetic field sensor element with associated electronics mounted in a fixed position in a sensor housing; a first sacrificial material coupon mounted in a fixed position in the immediate vicinity of the magnetic field sensor element, the first sacrificial material coupon being chosen to represent the material of the structure and being mounted so as to be exposed to the environment of the structure; wherein the associated electronics is effective to capture and record magnetic field strength or magnetic fluxes over time as measured by the first magnetic field sensor element further including rigidly fixing the first sacrificial material coupon directly to the structure.
Another aspect of the invention is a method for measuring environmental degradation in the environment of a structure comprising the steps of: mounting a first magnetic field sensor element with associated electronics in a fixed position in a sensor housing, the sensor housing mounted in close proximity to the structure; mounting a first sacrificial material coupon in a fixed position in the immediate vicinity of the magnetic field sensor element, wherein the first sacrificial material coupon is chosen to represent the material of the structure and is mounted so as to be exposed to the environment of the structure; and capturing and recording magnetic field strength or magnetic fluxes over time as measured by the first magnetic field sensor element and using those recordings to measure the environmental degradation in the environment of the structure.
Another aspect of the invention is a method for measuring environmental degradation in the environment of a structure comprising the steps of: mounting a first magnetic field sensor element with associated electronics in a fixed position in a sensor housing, the sensor housing mounted in close proximity to the structure; mounting a first sacrificial material coupon in a fixed position in the immediate vicinity of the magnetic field sensor element, wherein the first sacrificial material coupon is chosen to represent the material of the structure and is mounted so as to be exposed to the environment of the structure; mounting a second sacrificial material coupon in a fixed position in the immediate vicinity of a second magnetic field sensor element with associated electronics, the second material coupon mounted so as to not be exposed to the environment of the structure; wherein the second sacrificial material coupon is of the same material of the first sacrificial material coupon; and recording differences in magnetic field strengths detected between the first and the second magnetic field sensor elements over time, and using those recordings to measure the environmental degradation in the environment of the structure.
Another aspect of the invention is a method for measuring environmental degradation in the environment of a structure comprising the steps of: mounting a first magnetic field sensor element with associated electronics in a fixed position in a sensor housing, the sensor housing mounted in close proximity to the structure; mounting a first sacrificial material coupon in a fixed position in the immediate vicinity of the magnetic field sensor element, wherein the first sacrificial material coupon is chosen to represent the material of the structure and is mounted so as to be exposed to the environment of the structure; further including rigidly fixing the first sacrificial material coupon directly to the structure and; capturing and recording magnetic field strength or magnetic fluxes over time as measured by the first magnetic field sensor element and using those recordings to measure the environmental degradation in the environment of the structure.
To insure that a clear and complete explanation is given to enable a person of ordinary skill in the art to practice the invention some specific examples will be given involving applying the instant invention to particular structures and with particular magnetic field sensors. It should be understood though that the inventive concept could apply to other structures, using other magnetic field sensors and the specific example is not intended to limit the inventive concept to the example application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side and top view of one aspect of the invention.
FIG. 2 is a side and top view of one aspect of the invention.
FIG. 3 is a side and top view of one aspect of the invention.
DETAILED DESCRIPTION
FIG. 1 represented generally by the numeral 100 illustrates an aspect of the instant invention. A magnetic sensor element 130 is mounted in a fixed position in a sensor housing 120 . The sensor housing 120 is mounted on or in close proximity to the structure 140 that is being monitored. The sensor housing could be made of any number of non-magnetic materials, such as aluminum, or a plastic material. Mounted in close proximity or in direct contact to sensor element 130 is a sacrificial material coupon 110 . Sacrificial material coupon 110 is chosen to match the material of structure 140 . As shown in FIG. 1 a significant portion of sacrificial material coupon 110 is exposed to the environment surrounding structure 140 . Element 150 is a spacer or gasket to aid in mounting sacrificial material coupon 110 and is not critical to the instant invention. It should be noted that FIG. 1 indicates a sensor housing 120 as being made up of separate parts but could also be an integral single piece surrounding sensor housing 120 and sacrificial material coupon 110 . Not shown in the FIG. 1 is the electronics associated with sensor element 130 that would capture and record magnetic field strength or magnetic fluxes over time. The data collected could be stored integrally in memory in sensor housing 120 , or transmitted by wiring or wirelessly to remote environmental monitoring equipment.
Magnetic sensor 130 could for example be a AD22151G linear output magnetic field transducer (Hall Effect) manufactured by Analog Devices of Norwood, Mass. Alternately a giant magnetoresistance detector such as model AAH-004-00 magnetometer, manufactured by NVE Corporation of Eden Prairie, Minn. These sensors, as well as select eddy current sensors are suited to this application.
FIG. 2 , represented generally by the numeral 200 , illustrates a further application of the instant invention. A first magnetic sensor element 230 is mounted in a fixed position in a sensor housing 220 . The sensor housing 220 is mounted on or in close proximity to the structure 240 that is being monitored. The sensor housing could be made of any number of non-magnetic materials, such as aluminum, or a plastic material. Mounted in close proximity or in direct contact to sensor element 230 is a sacrificial material coupon 210 . Sacrificial material coupon 210 is chosen to match the material of structure 240 . As shown in FIG. 2 a significant portion of sacrificial material coupon 210 is exposed to the environment surrounding structure 240 . A second magnetic sensor element 235 is mounted in a fixed position in a sensor housing 220 . A second sacrificial material coupon 225 is mounted in close proximity or in contact with magnetic sensor element 235 . Sacrificial material coupon 225 is sealed from exposure to the environment by being sealed inside sensor housing 220 . In practice magnetic sensor elements 230 and 235 would be identical in nature, as would the material of sacrificial material coupons 210 and 225 . Magnetic sensor elements 210 and 235 are in communication, either wired or wirelessly with a differential measurement system 250 to measure and record the differences in magnetic field or magnetic flux measurements. This aspect of the invention allows environmental degradation to be measured as the difference between two relatively identical sacrificial material coupons, one being exposed to the environment and the other not exposed. It should be noted that although the two sensor housings are shown as separate, in practice this could be an integral sensor housing.
FIG. 3 , represented generally by the numeral 300 , represents another embodiment of the instant invention. In some applications it is desired to measure the environmental degradation of a sacrificial material coupon experiencing the same stress history as the underlying structure. In this embodiment the sensor housing 320 , containing the fixed magnetic sensor element 330 is mounted onto structure 340 . Sacrificial material coupon 310 is placed in close proximity to magnetic sensor element 330 but in addition is rigidly fixed to structure 340 with mounting elements 350 . Other means, such as a load frame (not shown) could be used couple the sacrificial material coupon to the structure. Not shown in FIG. 3 is the electronics associated with sensor element 330 that would capture and record magnetic field strength or magnetic fluxes over time. The data collected could be stored integrally in memory in sensor housing 320 , or transmitted by wiring or wirelessly to remote environmental monitoring equipment.
Processing of the data from these various aspects of the invention is used to monitor corrosion. A number of possibilities exist. Field strength as measured by the sensor is proportional to current, which is proportional to actual damage. The corrosion magnetic field contains spatial and temporal information that correlate with the distribution, magnitude, and time course of currents associated with electrochemical corrosion. In conjunction with appropriate calibration experiments, the magnetic activity of a corroding sample can be used for non-destructive and real-time quantification of electrochemical corrosion activity of non-ferromagnetic metals.
In practice the practitioner would continuously integrate the measured field to thus have a measure of corrosion damage from time zero to current time. In addition the collected data allows the accumulation of a time history of the amount and rate of corrosion damage.
Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered obvious and desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A sensor apparatus for measuring environmental degradation of a structures making use of exposed sacrificial material coupons mounted in the immediate vicinity of magnetic sensor elements in the environment of the monitored structure. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Phase filing under 35 U.S.C. §371 of International Application PCT/US2011/053865, filed Sep. 29, 2011, and published as WO 2012/050951 on Apr. 19, 2012. PCT/US2011/053865 claimed benefit of priority to U.S. Provisional Application No. 61/404,235, filed Sep. 29, 2010. The entire contents of each of the prior applications are hereby incorporated herein by reference.
TECHNICAL FIELD
The present invention generally relates to vinyl ether functional oligomers and their use in forming polymers.
BACKGROUND INFORMATION
Oligomers bearing polymerizable functional groups are very important in many commercial applications including coatings, adhesives and composites. These reactive oligomers provide critical film-forming, adhesive, flexural and impact modification that are essential for success in those applications. Vinyl ether polymers and oligomers constitute a classical group of starting materials for the production of adhesives and coatings. They are primarily used in combination with other raw materials or in making pressure-sensitive adhesives, usually by blending with acrylic dispersions. In the field of surface coatings, polyvinyl ethers are formulated together with cellulose nitrate, chlorinated binders, and styrene copolymers for coating metal foil, plastics, film, paper, and other flexible substrates, and for antifouling paints. Oligomers bearing polymerizable functional groups are especially important in the fields of UV and electron-beam curing where polymerization takes place at time scales of the order of seconds. In such cases, oligomers bearing polymerizable functional groups not only provide film-forming characteristics, but also allow uniform application, control flow, and limit penetration into porous substrates. Especially valuable is the use of these oligomers to control shrinkage and enhance the efficiency of crosslinking during photopolymerization.
SUMMARY OF THE INVENTION
The vinyl ether functional oligomer compositions of this invention have many applications including radiation curable coatings, adhesives, printing inks and composites. In addition, these oligomers have additional potential uses in imaging applications such as photoresists and for 3-dimensional imaging techniques such as ink jet printing and stereolithography.
In one aspect, the invention includes an oligomer comprising repeating units of formula I
wherein
R 1 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon;
R 2 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon; and
R 3 is a non-olefinic and non-acetylenic (C 1 -C 24 )hydrocarbon, wherein one or more alkylene (CH 2 ) optionally may be replaced by —O—, —S—, or SO 2 in each instance.
In a second aspect, the invention includes an oligomer obtainable by the process comprising preparing a mixture of
a. at least one monomer of formula A
R 2 O 2 C—CH═CH—CO 2 R 1 A
wherein R 1 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon; R 2 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon; and b. at least one monomer of formula B
wherein R 3 is a non-olefinic and non-acetylenic (C 1 -C 24 )hydrocarbon group, wherein one or more alkylene (CH 2 ) optionally may be replaced by —O—, —S—, or SO 2 in each instance; in the presence of a free radical initiator in a solvent with a high radical chain transfer constant,
wherein the molar ratio of the monomer of formula A to the monomer of formula B is approximately 1:1.
In a third aspect, the invention includes a composition comprising:
a. A monomer of formula A
R 2 O 2 C—CH═CH—CO 2 R 1 A;
b. A monomer of formula B
c. A solvent with a high radical chain transfer constant;
wherein
R 1 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon;
R 2 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon;
R 3 is a non-olefinic and non-acetylenic (C 1 -C 24 )hydrocarbon, wherein one or more alkylene (CH 2 ) optionally may be replaced by —O—, —S—, or SO 2 in each instance; and wherein the molar ratio of the monomer of formula A to the monomer of formula B is approximately 1:1.
In a fourth aspect, the invention includes a method for preparing an oligomer, said method comprising preparing a mixture of
a. at least one monomer of formula A
R 2 O 2 C—CH═CH—CO 2 R 1 A
wherein R 1 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon; R 2 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon; and b. at least one monomer of formula B
wherein R 3 is a non-olefinic and non-acetylenic (C 1 -C 24 )hydrocarbon, wherein one or more alkylene (CH 2 ) optionally may be replaced by —O—, —S—, or SO 2 in each instance;
in the presence of a free radical initiator in a solvent with a high radical chain transfer constant;
wherein the ratio of the monomer of formula A to the monomer of formula B is approximately 1:1.
In a fifth aspect, the invention includes a kit for preparing oligomers comprising:
a. a mixture comprising
i. at least one monomer of formula A
R 2 O 2 C—CH═CH—CO 2 R 1 A
wherein R 1 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon; R 2 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon;
ii. at least one monomer of formula B
wherein R 3 is a non-olefinic and non-acetylenic (C 1 -C 24 )hydrocarbon, wherein one or more alkylene (CH 2 ) optionally may be replaced by —O—, —S—, or SO 2 in each instance; in a solvent with a high radical chain transfer constant;
wherein the ratio of the monomer of formula A to the monomer of formula B is approximately 1:1; and
b. a second component comprising a free radical initiator, optionally in a solvent with a high radical chain transfer constant.
In a sixth aspect, the invention includes a process for forming a polymer comprising:
a. Combining at least one oligomer of the invention with a cationic photoinitiator; and b. Exposing the resulting combination to actinic irradiation.
In a seventh aspect, the invention includes a process for forming a polymer comprising:
a. Combining at least one oligomer of the invention, at least one free radically polymerizable vinyl monomer and a free radical photoinitiator; and b. Exposing the resulting combination to actinic irradiation.
These and other objects, features and advantages of this invention will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying examples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an OP study of the photopolymerization of diethylmaleate/1,4-butanediol divinyl ether (DEM-BDDVE) reactive oligomer with 2% by weight of (4-octyloxyphenyl)-phenyliodonium hexafluoroantimonate (IOC-8SbF 6− ) as the photoinitiator (light intensity 2700 mJ/cm 2 min.), in accordance with the present invention.
FIG. 2 shows cationic photopolymerization of DEM-BDDVE reactive oligomer with 50% by weight of BDDVE using 2% by weight of IOC −8 SbF 6− as the photoinitiator (light intensity 2700 mJ/cm 2 min.), in accordance with the present invention.
FIG. 3 presents free radical photopolymerization of DEM-BDDVE reactive oligomer with one equivalent of DEM using 2% by weight of Darocure-1173 as the photoinitiator (light intensity 2700 mJ/cm 2 min.), in accordance with the present invention.
FIG. 4 depicts the free radical photopolymerization of the vinyl ether functional CMDVE-DEM oligomer with equivalent amounts of either DEM or DMM using 3% Irgacure 184 (1-hydroxycyclohexylphenyl ketone) as the photoinitiator (light intensity 2700 mJ/cm 2 min.), in accordance with the present invention.
FIG. 5 shows the free radical photopolymerization of DEM-DVE-3 oligomer with 50% 1,6-hexanediol diacrylate with 3% Darocure-1173 (light intensity 2700 mJ/cm 2 min.), in accordance with the present invention.
FIG. 6 shows an OP study of the photopolymerization of a 1:1 molar mixture of DBM-DVE-3 oligomer with DMM with 3% by weight of Darocure-1173 (light intensity 2700 mJ/cm 2 min.), in accordance with the present invention. Duplicate runs are shown.
FIG. 7 shows an OP study of the photopolymerization of a 2:1 wt/wt mixture of DEF-DVE-3 oligomer with 1,6-hexanediol diacrylate with 3% by weight of Darocure-1173 (light intensity 2700 mJ/cm 2 min.), in accordance with the present invention. Duplicate runs are shown.
Photoinitiated free radical alternating copolymerizations of dialkylmaleates or dialkylfumarates together with multifunctional vinyl ethers occur only when both types of monomers are present. As a result, copolymers are formed. Neither the maleate or fumarate monomer, nor the vinyl ether monomer, undergoes free radical polymerization by itself (i.e. homopolymerization). When the photocopolymerizations of these two classes of monomers are carried out in a stoichiometric 2:1 ratio with a divinyl ether (as depicted in equation 1), a crosslinked network copolymer is formed. The photopolymerizations of dialkyl maleates and dialkyl fumarates with multifunctional vinyl ethers are fast and efficient, and the network copolymers that are obtained are transparent and colorless. Depending on the respective three R groups in the monomers, copolymers that are obtained range from stiff, brittle and glass-like to highly flexible.
In this invention, a modification of the stoichiometry shown in equation 1 leads to the production of reactive oligomers bearing vinyl ether groups. The average functionality of a mutually reactive multicomponent system s determined by the functionality of the minority component present in the mixture (G. Odian, Principles of Polymerization, 4th Ed., Wiley-Interscience, New York, 2005, pp. 105-108.). Thus, as shown below in equation 2, a 1:1 equimolar mixture of a dialkyl maleate- or fumarate-based monomer (difunctional, formula A) with a divinyl ether (tetrafunctional, formula B) has an average functionality of 2. As depicted in equation 2, a linear or branched alternating copolymer can be formed bearing pendant vinyl ether groups. The polymer does not crosslink easily and is, therefore, soluble in common solvents or monomers.
Reactive oligomers such as those described in equation 2 bearing pendant vinyl ether groups are of considerable interest for a variety of potential uses. For example, these oligomers would be particularly advantageous for use in UV curing applications. As noted in equation 2, the reactive oligomer could be combined with the same or a different dialkyl maleate- or fumarate-based monomer and then photopolymerized using a free radical photoinitiator. In addition to dialkyl maleates and fumarates, other free radically polymerizable vinyl monomers can be used. For example, the oligomers of this invention can be photopolymerized with mono- or multifunctional acrylates and methacrylates.
Alternatively, the same reactive vinyl ether functional oligomer could be directly mixed with a cationic photoinitiator and then UV irradiated to give a crosslinked network. In this case, crosslinking occurs by direct homopolymerization of the vinyl ether groups located along the backbone of the oligomer. A further modification consists of adding low molecular weight mono-, di- or multifunctional vinyl ethers to the oligomer and then performing the cationic photopolymerization. Since vinyl ether monomers are extraordinarily reactive under cationic polymerization conditions, these two strategies would appear to give rise to very rapidly curing compositions well suited to high volume, high speed applications such as printing inks and coatings. A further expectation from the use of these oligomers in either free radical or cationic photopolymerization is the substantial reduction in shrinkage that occurs when they are used. Essentially, a great deal of the overall shrinkage is removed by first making the oligomers and then subjecting them to a further crosslinking photopolymerization.
A large number of attempts were made to carry out the copolymerization of 1:1 mixtures of various dialkyl maleates or dialkyl fumarates with difunctional vinyl ethers in the presence of such free radical initiators as benzoyl peroxide and AIBN. Although theory might predict that linear or branched polymers should result, invariably, when these copolymerizations were conducted in the absence of a solvent, gelled (i.e. crosslinked) products were obtained. On the other hand, when the copolymerizations of maleate and fumarate monomers with divinyl ethers were conducted in the presence of a solvent with a high radical chain transfer constant, the polymerization was surprisingly successful.
The methodology depicted in equation 2 is readily applicable to the synthesis of a wide range of vinyl ether functional oligomers. Each of the three R groups shown in this equation can be varied to provide oligomers with a broad array of chemical, mechanical and physical properties on cure. The molecular weight and viscosity of the oligomers can be controlled by the concentration of the free radical initiator employed in the synthesis. Typically, the oligomers described here are colorless or very pale yellow colored viscous fluids. The oligomers can be used directly as prepared in various applications or further diluted with various maleate, fumarate, acrylate, methacrylate, styrenic or vinyl ether monomers to provide photo—, electron-beam or thermally curable mixtures.
It is also worth noting that multifunctional vinyl ethers are rather high priced materials. For this reason, multifunctional vinyl ethers cannot compete with acrylates in most UV cure applications. On the other hand, dialkyl maleates or dialkyl fumarates are very inexpensive materials. The strategy of copolymerization of multifunctional vinyl ethers with maleates and fumarates is attractive since it results in an overall systems cost reduction together with an upgrade in chemical, mechanical and physical properties.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
Throughout this specification and in all independent claims the terms and substituents retain their definitions.
Hydrocarbon refers to any substituent comprised of hydrogen and carbon as the only elemental constituents. Unless otherwise specified, hydrocarbon includes alkyl, polycycloalkyl, alkenyl, alkynyl, aryl and combinations thereof. Examples include benzyl, phenethyl, cyclohexylmethyl, dimethylcyclohexane and naphthylethyl. Although the definition of hydrocarbon includes alkenyl and alkynyl, those hydrocarbons that contain double and triple bonds are excluded from the present invention. C 1 to C 10 hydrocarbon [or (C 1 -C 10 )hydrocarbon] includes any hydrocarbon containing 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 carbon atoms, along with their corresponding hydrogen atoms. Similarly, C 1 to C 24 hydrocarbon includes any hydrocarbon containing 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23 or 24 carbon atoms, along with their corresponding hydrogen atoms.
Unless otherwise specified, alkyl is intended to include linear, branched, or cyclic hydrocarbon structures and combinations thereof. A combination would be, for example, dimethylcyclohexane. C 1 to C 8 alkyl [or (C 1 -C 8 )alkyl] refers to alkyl groups containing 1, 2, 3, 4, 5, 6, 7 or 8 carbon atoms. Examples of (C 1 -C 8 )alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, s- and t-butyl and the like. Cycloalkyl is a subset of alkyl and includes cyclic hydrocarbon groups containing 3 to 8 carbon atoms. Examples of cycloalkyl groups include c-propyl, c-butyl, c-pentyl, c-hexyl, norbomyl and the like.
Oxaalkyl refers to alkyl residues in which one or more carbons (and their associated hydrogens) have been replaced by oxygen. Non-limiting examples include methoxypropoxy, ethoxyethane and diethoxymethane. The term oxaalkyl is intended as it is understood in the art [see Naming and Indexing of Chemical Substances for Chemical Abstracts , published by the American Chemical Society, ¶196, but without the restriction of ¶127(a)], i.e. it refers to compounds in which the oxygen is bonded via a single bond to its adjacent atoms (forming ether bonds); it does not refer to doubly bonded oxygen, as would be found in carbonyl groups.
According to IUPAC, a polymer is “a molecule of high relative molecular mass, the structure of which essentially comprises the multiple repetition of units derived, actually or conceptually, from molecules of low relative molecular mass.” Also according to IUPAC, an oligomer is “a molecule of intermediate relative molecular mass, the structure of which essentially comprises a small plurality of units derived, actually or conceptually, from molecules of lower relative molecular mass.” For the purpose of the present invention we define the cutoff between oligomer and polymer to occur at 100 repeating units of A plus B in total. Thus a molecule that comprises 50 repeating units A and 50 repeating units B (or fewer) is an oligomer; a molecule that comprises 51 repeating units A and 51 repeating units B is a polymer.
Examples of monofunctional or multifunctional acrylates and monofunctional or multifunctional methacrylates that can be free radically polymerized include: ethylene glycol diacrylate, allyl acrylate, hydroxyethylacrylate, 1,4-butanediol diacrylate, isobornyl acrylate, n-butyl acrylate, lauryl acrylate, trimethylolpropane triacrylate, pentaerythritol tetraacrylate, trimethylolethane triacrylate, bisphenol-A-diacrylate, diethylene glycol diacrylate, triethylene glycol diacrylate, dipentaerythritol hexaacrylate, 1,4-cyclohexanedimethanol diacrylate, ethylene glycol dimethacrylate, 1,6-hexanediol dimethacrylate, hydroxyethylmethacrylate and polyurethane diacrylate oligomers. Among other possible free radically polymerizable monomers are: dimethyl maleate, dimethyl fumarate, diethyl maleate, di-n-butyl maleate, di-n-octylmaleate, diethylfumarate, dimethylitaconate.
In one aspect, the invention includes an oligomer comprising repeating units of formula I
In some embodiments of the invention, the oligomer further comprises a plurality of units of formula II
It is important to note that the repeating units may be in any order, and it is not necessary for more than one unit of formula I to be adjacent to another, although that may be the case in some instances. Although the oligomer may contain units such as structure II, on average the main units are those of structure I.
In some embodiments of the invention, R 1 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon. In some embodiments, R 1 is methyl. In other embodiments, R 1 is ethyl. In still other embodiments, R 1 is propyl. In yet other embodiments, R 1 is butyl. In some embodiments, R 1 is 2-ethylhexyl.
In some embodiments of the invention, R 2 is a non-olefinic and non-acetylenic (C 1 -C 10 )hydrocarbon. In some embodiments, R 2 is methyl. In other embodiments, R 2 is ethyl. In still other embodiments, R 2 is propyl. In yet other embodiments, R 2 is butyl. In some embodiments, R 2 is 2-ethylhexyl.
In some embodiments of the invention, R 3 is a non-olefinic and non-acetylenic (C 1 -C 24 )hydrocarbon. In some embodiments of the invention, one or more alkylene (CH 2 ) may be replaced by —O—. In other embodiments of the invention, one or more alkylene (CH 2 ) may be replaced by —S—. In still other embodiments of the invention, one or more alkylene (CH 2 ) may be replaced by SO 2 . It is important to note that each replaced alkylene (CH 2 ) may be replaced by any one of —O—, —S—, or SO 2 . The person of skill in the art will be aware of those replacements that are not chemically stable; residues that are chemically stable are preferred. In some embodiments of the invention, R 3 is one of the two formulae below:
In some embodiments, X is a direct bond. In other embodiments, X is C(CH 3 ) 2 or CH 2 . In still other embodiments, X is O. In yet other embodiments, X is S or SO 2 . In other embodiments of the invention, R 3 is selected from (C 1 -C 8 )alkyl and (C 1 -C 8 )oxaalkyl. Some non-limiting examples of R 3 include
—CH 2 —CH 2 —O—CH 2 —CH 2 —, and —CH 2 —CH 2 —O—CH 2 —CH 2 —O—CH 2 —CH 2 —.
In other embodiments, the invention relates to an oligomer obtainable by the process comprising reacting at least one monomer of formula A
R 2 O 2 C—CH═CH—CO 2 R 1 A
with at least one monomer of formula B
in the presence of a free radical initiator in a solvent with a high radical chain transfer constant. In these embodiments, the ratio of the monomer of formula A to the monomer of formula B is approximately 1:1.
The free radical initiator of the invention preferably has a convenient half life and undergoes fragmentation by thermolysis to give pH neutral products that do not interfere with the subsequent radical or cationic polymerizations. Additionally, these fragments react further with the vinyl ether groups present in the oligomeric product. In some embodiments of the invention, the free radical initiator is an azo inhibitor. In other embodiments, the free radical initiator is a peroxy or hydroperoxy initiator. In still other embodiments, the free radical initiator is a peroxyalkyl initiator. In some embodiments, the free radical initiator is 2,2′-Azobisisobutyronitrile. The half-life of 2,2′-Azobisisobutyronitrile (AIBN) is 80 min at 80° C. Other suitable free radical initiators include benzoyl peroxide, dicumylperoxide, t-butyl hydroperoxide, cumene hydroperoxide, acetyl peroxide, lauroyl peroxide, t-butyl perbenzoate, t-butyl peroxypivalate, 2,2′-azobis-2-ethylpropionitrile, 4,4′-az0-bis(cyanopentanol) (a comprehensive list of applicable free radicals can be found in Polymer Handbook, 4 th Ed. Vol. 1, by J. Brandrup, E. H. Immergut and E. A. Grulke (editors) Wiley-Interscience, New York, 1999, p. II/1.
The chain transfer constant of the solvent may range from 10-60,000. Suitable solvents with known high free radical chain transfer constants are for example: p-dioxane; tetrahydrofuran, 1,3-dioxolane, 1,2-dimethoxyethane and diethyleneglycol dimethyl ether. A comprehensive list of applicable free radicals constants for various solvents and additives can be found in Polymer Handbook, 4 th Ed. Vol. 1, by J. Brandrup, E. H. Immergut and E. A. Grulke (editors) Wiley-Interscience, New York, 1999, p. II/111. The chain constants are a function of the specific solvent, the monomer(s) and the temperature at which the polymerization is carried out. Solvents with high transfer constants would be those with values above 1000.
In addition to having a high free radical chain transfer constant, the solvent should have a relatively low boiling point so that it may be readily removed from the oligomer by vacuum stripping and so that the copolymerization can be carried out in a convenient time period (less than 10 hours) under refluxing conditions. For instance, 1,2-dimethoxyethane is an excellent solvent for the two monomers and has a boiling point of 85°, which allows the copolymerization to be carried out in approximately 3-5 hours under refluxing conditions. In some embodiments of the invention, the solvent with a high radical chain transfer constant is 1,2-dimethoxyethane. In other embodiments, the solvent is 1,4-dioxane. In still other embodiments, the solvent is 1,3-dioxolane. In yet other embodiments, the solvent is tetrahydrofuran. In other embodiments, the solvent is diethylene glycol dimethyl ether. In some embodiments, the solvent is di(n-butyl)ether.
In some embodiments, the invention relates to a composition comprising a monomer of formula A:
R 2 O 2 C—CH═CH—CO 2 R 1 A;
a monomer of formula B:
and a solvent with a high radical chain transfer constant. In these embodiments, the ratio of the monomer of formula A to the monomer of formula B may be approximately 1:1. These compositions are useful in that they can be packaged and transported readily, and subsequently the oligomers described herein can be made simply by mixing these compositions with a suitable catalyst at an appropriate temperature.
In some embodiments, the invention relates to a process for preparing an oligomer comprising reacting a monomer of formula A with a monomer of formula B in the presence of a free radical initiator in a solvent with a high radical chain transfer constant. In these embodiments, the ratio of the monomer of formula A to the monomer of formula B may be approximately 1:1.
In some embodiments, the invention relates to a kit for preparing oligomers comprising two components. The first component comprises a mixture of a monomer of formula A with a monomer of formula B in a solvent with a high radical chain transfer constant. In these embodiments, the ratio of the monomer of formula A to the monomer of formula B approximately 1:1. The second component comprises a free radical initiator, optionally in a solvent with a high radical chain transfer constant.
In some embodiments, the invention relates to process for forming a polymer. In these embodiments, the process first comprises combining at least one oligomer as described above with a cationic photoinitiator. In some embodiments, the cationic photoinitiator is a diaryliodonium salt. In other embodiments, the cationic photoinitiator is a triarylsulfonium salt. In some embodiments, the cationic photoinitiator is (4-n-octyloxyphenyl)phenyliodonium hexafluoroantimonate (IOC-8 SbF 6 − ).
In some embodiments of the invention, additional amounts of the monomer of formula B may be added to the oligomer and the cationic photoinitiator. In some embodiments, this additional monomer of formula B is added in a molar amount equivalent to the vinyl ether groups present in the oligomer.
The resulting combination is then exposed to actinic irradiation. For instance, ultraviolet irradiation may be employed. The use of aromatic onium salts such as diaryliodonium and triarylsulfonium salts as photoacid generators in photolithography and as photoinitiators for cationic photopolymerizations is well documented. Most onium salts are intrinsically photoactive in the short and middle wavelength region of the UV spectrum and hence, no photosensitizer is required. However, photosensitizers are commonly added when radiation outside that range is employed. Polynuclear aromatic hydrocarbons such as anthracene, pyrene, and perylene have the requisite long wavelength absorption characteristics and also undergo efficient photoinduced electron-transfer photosensitization with onium salt photoinitiators. Other photosensitizers for diaryliodonium and triarylsulfonium salts are well-known in the art and can be employed in the compositions herein.
In other embodiments, the invention relates to another process for forming a polymer. In these embodiments, the process first comprises combining at least one oligomer as described above with at least one free radically polymerizable monomer and a free radical photoinitiator.
In some embodiments of the invention, the free radically polymerizable monomer is a monomer of formula A. In other embodiments; the free radically polymerizable vinyl monomer is styrene. In other embodiments, the free radically polymerizable monomer is a monofunctional or multifunctional acrylate. In still other embodiments, the free radically polymerizable monomer is a monofunctional or multifunctional methacrylate. In some embodiments, the free radically polymerizable monomer is a monomer of formula A added at a molar equivalent to that of the oligomer (that is, a molar equivalent amount of A to the amount of vinyl ether groups present in the oligomer).
In some embodiments of the invention, the free radical photoinitiator is selected from 2-hydroxy-2,2-dimethoxyacetophenone, 1-hydroxycyclohexylphenyl ketone, 2,2-dimethoxy-2-phenylacetophenone, bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide, 2,4,6-trimethylbenzoyldiphenylphosphine oxide, n-butylbenzoin ether, mixtures of benzophenone and triethanol amine and 4,4′-bis(N,N-dimethylamino)benzophenone. Other examples of appropriate free radical photoinitiators can be found in J. V. Crivello and K. K. Dietliker, “Photoinitiators for Cationic Polymerization” Chemistry and Technology of UV & EB Formulation for Coatings, Inks & Paints, 1991, E.M. Books, Ltd., London, Volume III, P. K. T. Oldring, Editor, p. 327.
The configuration of any carbon-carbon double bond appearing herein is selected for convenience only and is not intended to designate a particular configuration; thus a carbon-carbon double bond depicted arbitrarily herein as trans may be cis, trans, or a mixture of the two in any proportion. Similarly, when the compounds described herein contain olefinic double bonds or other centers of geometric asymmetry, and unless specified otherwise, it is intended that the compounds include both E and Z geometric isomers. For example, unless otherwise specified, a drawn structure could represent either diethyl maleate or diethyl fumarate. Likewise, all tautomeric forms are also intended to be included.
Although this invention is susceptible to embodiment in many different forms, preferred embodiments of the invention are shown. It should be understood, however, that the present disclosure is to be considered as an exemplification of the principles of this invention and is not intended to limit the invention to the embodiments illustrated.
Abbreviations
AIBN=2,2′-Azobisisobutyronitrile
BDDVE=1,4-butanediol divinyl ether
CHDDVE=1,4-cyclohexanedimethanol divinyl ether
DBM=dibutyl maleate
DEM=diethyl maleate
DMM=dimethyl maleate
DVE-3=triethyleneglycol divinyl ether
IOC-8 SbF 6 − =(4-n-octyloxyphenyl)phenyliodonium hexafluoroantimonate
OP=optical pyrometry
TMPTVE=trimethylolpropane trivinyl ether
UV=Ultraviolet
EXAMPLES
Explained herein are examples of embodiments of the invention. The invention may, however, be embodied in many different forms and should not be construed as being limited to the exemplary embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will convey the concept of the invention to those skilled in the art.
FIG. 1 is an OP study of the photopolymerization of DEM-BDDVE reactive oligomer with 2% by weight of IOC-8 SbF6− as the photoinitiator (light intensity 2700 mJ/cm2 min.). A description of the Optical Pyrometry apparatus and methods for its use are to be found in: B. Falk, S. M Vallinas and J. V. Crivello “Monitoring Photopolymerization Reactions Using Optical Pyrometry” J. Polym. Sci., Part A: Polym. Chem. Ed., 41(4), 579-596 (2003).
FIG. 2 shows photopolymerization of DEM-BDDVE reactive oligomer with 50% by weight of BDDVE using 2% by weight of IOC-8 SbF6− as the photoinitiator (light intensity 2700 mJ/cm2 min.).
FIG. 3 presents photopolymerization of DEM-BDDVE reactive oligomer with one equivalent of DEM using 2% by weight of Darocure-1173 as the photoinitiator (light intensity 2700 mJ/cm2 min.).
FIG. 4 depicts the free radical photopolymerization of the vinyl ether functional CMDVE-DEM oligomer with equivalent amounts of either DEM or DMM using 3% Irgacure 184 (1-hydroxycyclohexylphenyl ketone) as the photoinitiator (light intensity 2700 mJ/cm2 min.).
FIG. 5 shows Photopolymerization of DEM-DVE-3 oligomer with 50% 1,6-hexanediol diacrylate with 3% Darocure-1173 (light intensity 2700 mJ/cm2 min.).
FIG. 6 shows an OP study of the photopolymerization of a 1:1 molar mixture of DBM-DVE-3 oligomer with DMM with 3% by weight of Darocure-1173 (light intensity 2700 mJ/cm2 min.). Duplicate runs are shown.
FIG. 7 shows an OP study of the photopolymerization of a 2:1 wt/wt mixture of DEF-DVE-3 oligomer with 1,6-hexanediol diacrylate with 3% by weight of Darocure-1173 (light intensity 2700 mJ/cm2 min.). Duplicate runs are shown.
Materials
The free radical photoinitiators Irgacure 184, and Darocure 1173 were provided as samples by the Ciba Specialty Chemicals, Inc., Basel, Switzerland. All the alkyl maleate and fumarate esters, 1,6-hexanediol diacrylate and 2,2′-azobisisobutyronitrile (AIBN) were used as purchased from the Aldrich Chemical Co., Milwaukee, Wis. and from TCI America, Portland, Oreg. A sample of triethylene glycol divinyl ether (DVE-3) was kindly provided by International Specialty Products, Wayne, N.J. Similarly, 1,4-butarediol divinyl ether (BDDVE), 1,4-cyclohexanedimethanol divinyl ether (CHDDVE) and trimethylolpropane trivinyl ether (TMPTVE) were supplied by the BASF Corporation, Ludwigshafen, Germany. The cationic photoinitiator, (4-n-octyloxyphenyl)phenyliodonium hexafluoroantimonate (IOC-8 SbF 6− ) was prepared as described previously (J. V. Crivello and J. L. Lee, J Polym Sci Part A: Polym Chem 1989, 27, 3951-3968). All other reagents and chemicals were used as purchased from the Aldrich Chemical Co.
Example 1
Preparation of Vinyl Ether Oligomers
DEM-DVE-3 Oligomer: Into a 2-neck 50 ml round bottom flask equipped with a nitrogen inlet, a magnetic stirrer and a reflux condenser were placed 1.72 g (0.01 mol) diethyl maleate, 2.02 g (0.01 mol) triethyleneglycol divinyl ether (DVE-3), 0.019 g (0.5 wt %) AIBN and 10 ml 1,2-dimethoxyethane. The reaction mixture was first flushed with nitrogen and then heated to 80° C. under a nitrogen atmosphere for 3 hours. After cooling, the reaction mixture was stripped of solvent on a rotary evaporator leaving a pale yellow oil (2.76 g, 74% yield). A significant amount of the oligomer was lost during handling. An infrared spectrum recorded on a Nicolet 4700 FT-IR spectrometer showed the presence of a prominent strong bands at 1616 cm−1 and 1734.5 cm−1 due respectively to the vinyl ether carbon-carbon double bonds and the carbonyl bond. At the same time, the band at 1404.8 cm −1 assigned to the maleate double bond of DEM was absent. This indicates that the alternating polymerization proceeds efficiently and quantitatively to produce the desired oligomer with the structure shown in equation 2 (R 1 , R 2 =ethyl; R 3 ═(—CH 2 CH 2 —O—CH 2 CH 2 —O—CH 2 CH 2 —).
The above reaction was repeated under slightly different reaction conditions.
Into a 2-neck 50 ml round bottom flask equipped with a nitrogen inlet, a magnetic stirrer and a reflux condenser were placed 5.16 g (0.03 mol) diethyl maleate, 6.06 g (0.03 mol) triethyleneglycol divinyl ether (DVE-3), 0.22 g (2.0 wt %) AIBN and 25 ml 1,2-dimethoxyethane. The reaction mixture was first flushed with nitrogen and then heated to 80-85° C. under a nitrogen atmosphere for 5 hours. After cooling, the reaction mixture was stripped of solvent on a rotary evaporator leaving a pale yellow oil (2.76 g, 74% yield).
Example 2
DEM-BDDVE Oligomer: There were combined in a 2-neck 50 ml round bottom flask equipped with a nitrogen inlet, a magnetic stirrer and a reflux condenser 5.16 g (0.03 mol) diethyl maleate, 4.26 g (0.03 mol) 1,4-butanediol divinyl ether (BDDVE), 0.19 g (2 wt %) AIBN and 25 ml 1,2-dimethoxyethane. The reaction mixture was first flushed with nitrogen and then heated to 80° C. under a nitrogen atmosphere for 4 hours. After cooling, the reaction mixture was stripped of solvent on a rotary evaporator leaving the desired vinyl ether functional oligomer as a pale yellow oil (11 g, 100% yield).
Example 3
DEM-CMDVE Oligomer
There were combined in a 2-neck 50 ml round bottom flask equipped with a nitrogen inlet, a magnetic stirrer and a reflux condenser 5.16 g (0.03 mol) diethyl maleate, 5.88 g (0.03 mol) 1,4-cyclohexanedimethanol divinyl ether (CMDVE), 0.19 g (2 wt %) AIBN and 25 ml 1,2-dimethoxyethane. The reaction mixture was first flushed with nitrogen and then heated to 80° C. under a nitrogen atmosphere for 4 hours. After cooling, the reaction mixture was stripped of solvent on a rotary evaporator leaving a pale yellow oil (11.5 g, 100%). An infrared spectrum recorded on a Nicolet 4700 FT-IR spectrometer showed the presence of a prominent strong bands at 1616 cm −1 and 1734.5 cm −1 due respectively to the vinyl ether carbon-carbon double bonds and the carbonyl bond. At the same time, at 1404.8 cm 31 1 assigned to the maleate double bond of DEM was absent.
Example 4
DBM-DVE-3 Oligomer: There were combined in a 2-neck 50 ml round bottom flask equipped with a nitrogen inlet, a magnetic stirrer and a reflux condenser 6.84 g (0.03 mol) dibutyl maleate, 6.06 g (0.03 mol) DVE-3, 0.25 g (2 wt %) AIBN and 25 ml 1,2-dimethoxyethane. The reaction mixture was first flushed with nitrogen and then heated to 80° C. under a nitrogen atmosphere for 5 hours. After cooling, the reaction mixture was stripped of solvent on a rotary evaporator leaving the desired vinyl ether functional oligomer as a pale yellow oil (13.9 g, 100% yield). Product is overweight due to incorporation of solvent.
Example 5
DEF-BDDVE Oligomer: There were combined in a 2-neck 50 ml round bottom flask equipped with a nitrogen inlet, a magnetic stirrer and a reflux condenser 5.16 g (0.03 mol) diethyl fumarate, 4.26 g (0.03 mol) 1,4-butanediol divinyl ether (BDDVE), 0.09 g (1 wt %) AIBN and 25 ml 1,2-dimethoxyethane. The reaction mixture was first flushed with nitrogen and then heated to 80° C. under a nitrogen atmosphere for 4 hours. After cooling, the reaction mixture was stripped of solvent on a rotary evaporator leaving the desired vinyl ether functional oligomer as a pale yellow oil (g, % yield).
Photopolymerization of Vinyl Ether Functional Reactive Oligomers.
Vinyl ether functional reactive oligomer; are exceptionally versatile with respect to their utility in photocurable applications. As shown in Scheme 1, they can be photopolymerized in three different modes.
Mode #1. Cationic Photopolymerization
The most direct way in which vinyl ether functional reactive oligomers can be photopolymerized involves cationic polymerization. The addition of a cationic photoinitiator such as a diaryliodonium salt or a triarylsulfonium salt to the oligomer allows them to undergo polymerization on exposure to UV irradiation. An example is given in the sample temperature versus time plot shown in FIG. 1 determined by optical pyrometry (OP) in which an oligomer of diethyl maleate (DEM) and 1,4-butanediol divinyl ether (BDDVE) was combined with 2% by weight of (4-octyloxyphenyl)phenyliodonium hexafluoroantimonate (IOC-8 SbF 6 − ). The trace shows that the photopolymerization starts slowly and then accelerates as irradiation proceeds.
Mode #2. Cationic Photopolymerization
To demonstrate this mode of photopolymerization, the above DEM-BDDVE reactive oligomer was combined with an equivalent weight of BDDVE and 2% by weight of IOC-8 SbF 6 − based on the total weight of the mixture was added. The OP scan of the photopolymerization is shown in FIG. 2 . The results show that after a short induction period, the photopolymerization is exceedingly rapid with the temperature rising to nearly 170° C. The induction period is likely due to the presence of KOH added as a stabilizer to the BDDVE by the manufacturer (BASF).
Mode #3. Radical Photopolymerization
Combining a vinyl ether functional oligomer with a maleate or fumarate monomer and a free radical photoinitiator allows a free radical alternating photocopolymerization to take place. An example is given in FIG. 3 . In this experiment, an oligomer of DEM and BDDVE was combined with an equivalent of DEM and 2 wt % of 2-hydroxy-2,2-dimethylbenzophenone (Darocure-1173) Irradiation of the mixture as a thin film at 2700 mJ/cm 2 min in the optical pyrometer gave the curve shown. The mixture undergoes facile photopolymerization to provide a colorless, transparent, rigid film.
The polymerization with DMM is somewhat more rapid and exothermic than that with DEM. Both resulting polymers are rigid and transparent.
In FIG. 5 is shown the photopolymerization of the DEM-DVE-3 oligomer with 50% by weight of 1,6-hexanediol diacrylate. This polymerization is exceedingly fast and efficient. The copolymer film formed is quite hard and stiff. In the case of acrylate and methacrylate monomers that are added to the vinyl ether functional oligomers of this invention, amounts may be incorporated in amounts both equivalent to the molar amounts of vinyl ether groups present in the oligomer. Since these monomers also undergo free radical homopolymerization, they may also be added in amounts that exceed the molar amounts of the vinyl ether groups present in the oligomers.
While several aspects of the present invention have been described and depicted herein, alternative aspects may be effected by those skilled in the art to accomplish the same objectives. Accordingly, it is intended to cover all such alternative aspects as fall within the true spirit and scope of the invention. | The present invention includes vinyl ether functional oligomers and methods for their preparation, the method including alternating free radical copolymerization of a dialkyl maleate or dialkyl fumerate monomer with a multifunctional vinyl ether monomer in the presence of a solvent with a high chain transfer constant. Also within the scope of the invention are uses for the vinyl ether functional oligomers compositions of this invention, including radiation curable coatings, adhesives, printing inks and composites. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a synthesis method for producing nanosized noble metal particles suspended in pure solvents, such as water, lower alkyl alcohols and lower alkyl substituted aromatics, without additional separation and rinsing processes.
BACKGROUND OF THE INVENTION
[0002] Nanosized particles have attracted significant industrial interests. The unique size-dependent properties of nanosized materials have promising applications in catalysis, electronic and optical devices, and medical fields.
[0003] A number of syntheses, including chemical reduction, photochemical, sonochemical, and gas evaporation, have been developed to prepare nanosized metal particles. Among these, the chemical reduction method is well known as the most preferable method to synthesize nanosized metal particles. In the case of the chemical reduction method, however, reduction agents used for the fabrication could create contamination easily. Therefore, additional processes to remove the contaminants are necessary. Moreover, further processing is required to disperse the metal particles into a pure solvent.
[0004] The present invention overcomes these problems by providing a method whereby high purity noble metal particles suspended stably in pure solvent may be synthesized without additional processing to remove extraneous byproducts created during the fabrication process. Even though a laser ablation method recently reported looks like a unique process to create metal particles suspended in water, it is estimated to be an inefficient process in terms equipment cost and capability for mass production. The disclosed invention overcomes the inefficiencies of prior art production of suspended, high purity, nanosized metal particles in pure solvent and, additionally, has relatively low production costs.
SUMMARY OF THE INVENTION
[0005] An object of the invention is to solve at least the related art problems and disadvantages, and to provide at least the advantages described hereinafter.
[0006] Accordingly, it is an object of the present invention to provide methods for providing nanosized metal particles dispersed in a pure solvent. Other objects, features and advantages of the present invention will be set forth in the detailed description of preferred embodiments that follows, and in part will be apparent from the description or may be learned by practice of the invention. These objects and advantages of the invention will be realized and attained by the methods and compositions particularly pointed out in the written description and claims hereof.
[0007] In accordance with these and other objects, a first embodiment of the present invention is directed to a method for forming nanosized metal particles comprising: (i) dispersing a plurality of metal precipitates in a suitable solvent, each of the metal precipitates comprising at least one metal compound; and (ii) adding to the solvent an effective amount of at least one peroxide to form a product consisting essentially of a plurality of nanosized metal particles in the solvent.
[0008] A second embodiment of the present invention is directed to nanosized metal particles prepared by the methods disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows Ag particles having an average diameter of about 100 nm made according to the methods of the present invention.
[0010] FIG. 2 shows Ag particles having an average diameter of about 150 nm made according to the methods of the present invention.
[0011] FIG. 3 shows Ag particles having an average diameter of about 1,000 nm made according to the methods of the present invention.
[0012] FIG. 4 shows Au particles having an average diameter of about 40 nm made according to the methods of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0013] A first preferred embodiment of the present invention is directed to a method for forming nanosized metal particles comprising: (i) dispersing a plurality of metal precipitates in a suitable solvent, each of the metal precipitates comprising at least one metal compound; and (ii) adding to the solvent an effective amount of at least one peroxide to form a product consisting essentially of a plurality of nanosized metal particles in the solvent.
[0014] According to preferred embodiments, the present invention is directed to a method for forming nanosized metal particles suspended in pure solvents, such as water, lower alkyl alcohols, such as methanol, ethanol and isopropanol, and lower alkyl substituted aromatics, such as toluene and the various xylenes (o-xylene, m-xylene and p-xylene). According to the present invention, additional separation and cleaning processes are not necessary. Such processes for producing nanosized particles suspended in pure solvents, generally, comprise synthesis of nanosized metal particles through the reaction between a metal precipitate and a peroxide, such as hydrogen peroxide. Optionally, the methods of the present invention include the synthesis of a metal precipitate including at least one metal compound.
[0015] According to certain preferred embodiments of the present invention, the metal precipitate includes at least one metal compound selected from the group consisting of metal oxalates, metal sulfides, metal sulfates, metal oxides, metal hydroxides, metal nitrates, and metal carbonates. Precipitates containing mixtures of two or more of the aforementioned metal compounds may also be employed.
[0016] Preferably, the metal compound includes at least one noble metal. Non-limiting examples of noble metals include Rhenium(Re), Ruthenium(Ru), Rhodium(Rh), Palladium(Pd), Silver(Ag), Osmium(Os), Iridium(Ir), Platinum(Pt), and Gold(Au). Additionally, combinations of two or more noble metals may be employed in the methods disclosed herein.
[0017] Alternatively, other thermally decomposable metal compounds may be employed. Such thermally decomposable metal compounds are known to those skill in the art. Non-limiting examples of thermally decomposable metal compounds include compounds containing Gallium (Ga), Arsenic (As), Lead (Pb), Nickel (Ni), Iron (Fe), Chromium (Cr), Cobalt (Co), Vanadium (V), Beryllium (Be), Magnesium (Mg), Calcium (Ca), Strontium (Sr), and Barium (Ba). Additionally, combinations of two or more thermally decomposable metal compounds may be employed in the methods disclosed herein.
[0018] Alternatively, combinations of at least one noble metal compound and at least one other thermally decomposable metal compound may be employed in practicing the methods of the present invention.
[0019] According to certain preferred embodiments of the present invention, the metal precipitate is produced by reacting a source of metal ions with a base. Preferably, the metal ions are noble metal ions. Suitable sources of metal ions are known in the art. For instance, a solution containing metal salts may be formed by dissolving a metal salt in a solvent. Such metal salts are commercially available and/or may be prepared according to methods and techniques known in the art. For example, a solution containing Ag ions prepared by dissolving AgNO 3 in water.
[0020] According to the present invention, suitable bases are those that form a metal precipitate with the metal ions. Suitable bases may be determined empirically by one having ordinary skill in the art using methods and techniques known in the art. Non-limiting examples of suitable bases include oxalates, carbonates, acetates, nitrates, sulfates, hydroxides and combinations thereof. For instance, bases may be supplied by dissolving an appropriate salt in the solution containing metal ions. Preferred examples of such salts include, but are not limited to NaOH, NH 4 OH, Na 2 CO 3 , K 2 CO 3 , CaCO 3 , Cs 2 CO 3 , (NH 4 ) 2 CO 3 and the like. Such salts are commercially available and/or may be prepared according to methods and techniques known in the art.
[0021] According to the methods of the present invention, any suitable solvent may be used to prepare the metal precipitate. Non-limiting examples of suitable solvents include: water; lower alkyl alcohols, such as methanol, ethanol and/or isopropanol; lower alkyl substituted aromatics, such as toluene and/or the various xylenes; and mixtures thereof.
[0022] In still other preferred embodiments of the present invention, the solvent contains at least one surfactant and/or wetting agent. Suitable surfactants and wetting agents are known in the art.
[0023] Following formation of the metal precipitate, the precipitate is preferably separated from the solvent and washed with a solvent, such as distilled water. The precipitate may be separated from the solvent using methods and techniques known in the art, such as centrifugation and filtration. In other preferred embodiments of the present invention, the precipitate is washed multiple times with a solvent, such as water.
[0024] According to certain preferred embodiments of the present invention, the metal precipitate is sonicated, preferably in a small amount of solvent. Suitable sonication times may be determined empirically by one having ordinary skill in the art. Preferably, the metal precipitate is sonicated for 1 to 20 minutes per 100 mg of metal contents, more preferably 3 to 15 minutes, still more preferably 5 to 10 minutes and most preferably ten minutes, per 100 mg of metal contents. While ultrasonic waves are preferred for sonication, any suitable means of sonication known in the art may be employed.
[0025] To form the nanosized metal particles, the metal precipitate is first dispersed in a suitable solvent. Non-limiting examples of suitable solvents include: water; lower alkyl alcohols, such as methanol, ethanol and/or isopropanol; lower alkyl substituted aromatics, such as toluene and/or the various xylenes; and mixtures thereof. Preferably, the ratio of precipitate to solvent is about 100 mg of metal contents to about 0.010 to 3.0 liters of solvent.
[0026] In still other preferred embodiments of the present invention, the temperature of the solvent is above ambient temperature, preferably 50° C. to 100° C.
[0027] Following dispersion of the metal precipitate in the suitable solvent(s), a suitable peroxide, such as hydrogen peroxide, is added to the solvent containing the metal precipitate. The peroxide is added to the solvent in an amount effective to form a product consisting essentially of a plurality of nanosized metal particles in the solvent. Preferably, the peroxide is added in an amount of from 2 ml to 100 ml per 100 mg of metal contents, more preferably 5 ml to 70 ml, still more preferably 7 ml to 50 ml, and still even more preferably—10 ml to 30 ml, per 100 mg of metal contents.
[0028] The amount of peroxide will depend, at least in part, on the amount of metal precipitate employed and the size of the reaction vessel. Generally, as the amount of metal precipitate increases, the amount of peroxide required per unit metal precipitate decreases. Suitable amounts may be determined empirically by one having ordinary skill in the art.
[0029] Preferably, the hydrogen peroxide is added with stirring and/or while bubbling an inert gas through the solvent. Preferably, the inert gas is nitrogen or argon.
[0030] Nanosized metal particles having a broad range of average diameters may be produced according to the methods of the present invention. Preferably, the nanosized metal particles have an average diameter of 10 nm to 1,000 nm, more preferably 40 nm to 1,000 nm, and still more preferably 100 nm to 1,000 nm. Alternatively, the nanosized metal particles have an average particle size of 10 nm to 40 nm or 10 nm to 150 nm.
[0031] In order to remove any contaminating impurities remaining with the metal precipitate, it is preferable to rinse the metal precipitate with a solvent, such as distilled water. Optionally, the precipitate, together with a small amount of suitable solvent, is then sonicated. Preferably, the metal precipitate is sonicated for 1 to 20 minutes, more preferably 3 to 15 minutes, still more preferably 5 to 10 minutes and most preferably ten minutes, per 100 mg of metal precipitate.
[0032] According to the methods of the present invention, additional processing of the nanosized metal particles is not necessary, since the product produced consists essentially of the nanosized metal particles in the solvent. The nanosized metal particles may be separated from the solvent using techniques known in the art, such as centrifugation or filtration. For example, the nanosized metal particles and solvent are centrifuged at about 17,000 rpm for about 10 minutes.
[0033] The invention will now be illustrated using Silver (Ag). Water soluble silver salts, such as silver nitrate, silver sulfate, silver acetate, silver diamine nitrate, and silver diamine sulfate are preferred as a source of Ag ions. Silver carbonate or silver oxide precipitates are preferably used as silver compounds for the synthesis of nanosized silver particles. Precipitates of silver oxides or silver carbonate may be obtained, for instance, by adding NaOH or a carbonate compound, such as Na 2 CO 3 , K 2 CO 3 , CaCO 3 , Cs 2 CO 3 , (NH 4 ) 2 CO 3 , and the like, to a solution containing Ag ions.
[0034] Preferably, a mixture of hot solvent, such as water, and Ag carbonate precipitate are mixed in a ratio in the range of 0.01-3 liter per 100 mg of Ag contents. The precipitates are preferably thoroughly dispersed throughout the solvent. Hydrogen peroxide, preferably 10 ml to 30 ml per 100 mg of silver contents, is added to the resulting solution under magnetic stirring and nitrogen bubbling. Regardless of the amount of added solvent, all particles in the solution are decomposed to metallic Ag by reaction with hydrogen peroxide. The amount of hydrogen peroxide added may be varied according to the amount of metal precipitates.
[0035] A particular advantage of the present invention is that the high purity nanosized metal particles are formed in pure solvent and have no minor contaminants. Therefore, they may be synthesized without additional separation and/or rinsing processes after reaction.
[0036] The methods of the present invention result in a product consisting essentially of nanosized metal particles and the solvent. Such particles may be widely used in industrial and medicinal fields that require high purity nanosized metal particles. For instance, nanosized Ag particles made according to the methods of the present invention may be used in anti-bacterial agents, burn creams, ointments, preservatives and mineral supplements. Additionally, if such particles are produced in water, the resulting solution is essentially harmless for human consumption, since only water and Ag particles are present with essentially no other impurities. Such Ag particles may also be applied to anti-microbial materials in other medical fields and in electronics fields, for instance, as a conductive material.
EXAMPLES
[0037] The following examples are illustrative, but not limiting, of the present invention. Other suitable modifications and adaptations are of the variety normally encountered by those skilled in the art and are fully within the spirit and scope of the present invention. Example 1
[0038] Silver carbonate precipitates were made by completely mixing aqueous solutions of 10 ml of 0.1 M Na 2 CO 3 and 0.1 M 10 ml AgNO 3 at room temperature. The precipitates were rinsed several times with DI water. After the precipitates were sonicated by ultrasonic waves for 10 min, 1 liter of DI water at 50° C. to 100° C. was mixed with the precipitates. 10 ml of hydrogen peroxide were then added to the precipitate solution under nitrogen bubbling and magnetic stirring. The nanosized Ag particles were separated by centrifugation at 17,000 rpm for 10 min. As shown in FIG. 1 , Ag particles 1 having an average diameter of about 100 nm were obtained.
Example 2
[0039] Silver oxalate precipitates were made by completely mixing aqueous solution of 30 ml of 0.1M AgNO 3 and 30 ml of 0.1M sodium oxalate. The precipitates were rinsed multiple times with water. Then 8 ml of 5M sodium hydroxide was added to the precipitates. The precipitates were rinsed several times with water and 3 liter of water at 50 to 100° C. was mixed with the precipitates. 10 ml of hydrogen peroxide were then added to the precipitate solution under nitrogen bubbling and magnetic stirring. As shown in FIG. 2 , Ag particles 2 having an average diameter of about 150 nm were obtained. Example 3
[0040] Precipitates were made by completely mixing aqueous solutions of 10 ml 0.1M Na 2 CO 3 and 10 ml 0.1 AgNO 3 at room temperature. The precipitates were then rinsed with DI water. After the precipitates were sonicated by ultrasonic waves for 10 min, 70 ml of hydrogen peroxide were supplied to the precipitate solution. As shown in FIG. 3 Ag particles 3 having an average diameter of about 1 micron (1,000 nm) were obtained. Example 4
[0041] Gold oxide was prepared and rinsed several times with DI water. 1 liter of DI water at 50° C. to 100° C. was added to the gold oxide. 5-30 ml of hydrogen peroxide were added to the solution containing the gold oxide, under nitrogen bubbling. As shown in FIG. 4 , Au particles 4 having an average diameter of 10 to 40 nm sized were obtained.
[0042] Having now fully described this invention, it will be understood to those of ordinary skill in the art that the methods of the present invention can be carried out with a wide and equivalent range of conditions, formulations and other parameters without departing from the scope of the invention or any embodiments thereof.
[0043] All patents and publications cited herein are hereby fully incorporated by reference in their entirety. The citation of any publication is for its disclosure prior to the filing date and should not be construed as an admission that such publication is prior art or that the present invention is not entitled to antedate such publication by virtue of prior invention. | The present invention is directed to methods for forming nanosized metal particles. Preferably, nanosized noble metal particles are formed. According to the methods of the invention, a product containing nanosized metal particles in a solvent are formed. Additionally, processing to remove undesirable byproducts created or used during the fabrication process are not necessary. | 8 |
This is a division of application Ser. No. 08/279,635 filed Jul. 22, 1994, now U.S. Pat. No. 5,675,941, which is a continuation-in-part ("C.I.P.") of applications Ser. No. 08/012,986 filed Jan. 29, 1993, now U.S. Pat. No. 5,408,793 and Ser. No. 08/076,261 filed Jun. 11, 1993, now abandoned, Ser. No. 08/012,986 is in turn a continuation of Ser. No. 782,436 filed Oct. 25, 1991, now abandoned which is a divisional of 477,715 filed Feb. 9, 1990 (issued as U.S. Pat. No. 5,094,044) which is a divisional of Ser. No. 206,849 filed Jun. 15, 1988, now abandoned, a divisional of Ser. No. 559,911 filed Dec. 9, 1983 which issued a U.S. Pat. No. 4,776,145. Ser. No. 08/076,261 is a continuation of Ser. No. 07/797,904 filed Nov. 26, 1991, now abandoned, which is a continuation-in-part of Ser. No. 396,377 filed Aug. 21, 1989 (issued as U.S. Pat. No. 5,134,830) which is a C.I.P. of Ser. No. 915,269 filed Oct. 3, 1986 (issued as U.S. Pat. No. 4,879,859) which is a C.I.P. of Ser. No. 559,911 filed Dec. 9, 1983, now U.S. Pat. No. 4,776,145.
BACKGROUND OF THE INVENTION
This application represents a continuous evolution of the subject inventor's inventive technology relating to prestressed tanks or containment vessels. The field of the invention is containment structures and their construction which structures can be used to hold solid,liquids or gases. This invention is particularly useful in the construction of domed structures, utilizing a membrane and circumferential prestressing.
There has been a need for the improved construction of these types of structures as conventional construction has proven difficult and costly. Furthermore, these structures generally do not lend themselves to automation. For example, the current practice has been to construct roofs or domes of such tanks on scaffolding, shoring, framing or decking which is quite costly and time consuming, in contrast to the invention claimed herein where the roof is prefabricated and raised on a cushion of air.
Certain of these conventional structures have utilized prestressed concrete, reinforced concrete or steel tank construction, which are discussed below. Others have utilized Fiber Reinforced Plastic (FRP) and some have utilized inflated membranes.
Turning first to prestressed concrete tanks, their construction have typically utilized prestressing and shotcreting applied by methods set out in detail in U.S. Pat. Nos. 3,572,596; 4,302,978; 3,869,088; 3,504,474; 3,666,189; 3,892,367 and 3,666,190 issued to the subject inventor which are incorporated herein by reference. As set forth in these references, a floor, wall and roof structure is typically constructed out of concrete using conventional construction techniques. The wall is then prestressed circumferentially with wire or strand which is subsequently coated with shotcrete. The machinery used for this purpose is preferably automated, such as that set forth in the above patents. Shotcrete is applied to encase the prestressing and to prevent potential corrosion. As set out in more detail in these patents, and particularly U.S. Pat. No. 5,094,044, which is incorporated herein by reference, prestressing is beneficial in that concrete is not very good in tension but is excellent in compression. Accordingly, prestressing places a certain amount of compression on the concrete so that the tensile forces caused by the fluid inside the tank are countered not by the concrete, but by the compressive forces exerted on the concrete by the prestressing materials. Thus, if design considerations are met, the concrete is not subjected to the substantial tension forces which can cause cracks and subsequent leakage.
Major drawbacks of the above prestressed concrete tank structure are the need for expensive forming of the wall and roof and for substantial wall thickness to support the circumferential prestressing force which places the wall in compression. Furthermore, cracking and imperfections in the concrete structure can cause leakage. Also, conventional concrete tanks are generally not suitable for storage of certain corrosive liquids and petroleum products.
We now turn to tanks constructed using regular reinforcing. This second major category of concrete tanks typically utilize regular reinforcing (in contrast to prestressing), and no membrane. These tanks are inferior to the tanks utilizing circumferential prestressing because, while regular reinforcing makes the concrete walls stronger, it does not prevent the concrete from going into tension, making cracking and leakage an even greater possibility. Typically, reinforcing does not come into play until a load is imposed on the concrete is structure. It is intended to pick up the tension forces because, as previously explained, the concrete cannot withstand very much tension before cracking. Yet reinforcing does not perform this task very well because, unlike circumferential prestressing which preloads the concrete, there are no prestressing forces exerting on the concrete to compensate for the tension asserted by the loading. Moreover, as compared to prestressed concrete tanks, these reinforced concrete tanks require even more costly forming of wall and roof, and even greater wall thicknesses to minimize tensile stresses in the concrete, problems greatly eliminated with the subject invention.
Turning now to inflated membranes, such membranes, have been used for airport structures where the structure consists of the membrane itself. Inflated membranes have also been used to form concrete shells wherein a membrane is inflated and used as a support form. Shotcrete, with or without reinforcing, is sometimes placed over the membrane and the membrane is removed after the concrete is hardened. Another form of this construction is exemplified by conventional "Binishell" structures. Information regarding such structures is in the Disclosure Statement and in U.S. Pat. No. 3,462,521. These structures are constructed by placing metal springs, and regular reinforcing bars over an uninflated lower membrane. Concrete is then placed over the membrane and an upper membrane is placed over the concrete to prevent it from sliding to the bottom as the inflation progresses. The inner membrane is then inflated while the concrete is still soft. After the concrete has hardened, the membranes are typically removed. A major drawback of the afore-described conventional structures is the high cost connected with reinforcing and waterproofing them for liquid storage. Moreover, with regard to the "Binishell" structures, because of the almost unavoidable sliding of the concrete, it is difficult if not impossible to avoid honeycombing of the concrete and subsequent is leaks. Also Bini does not teach the utilization of membranes in conjunction with circumferential prestressing, in contrast to using mere reinforcing. As a result, these structures have not been very well received in the marketplace and have not, thus far, displaced the more popular and commercially successful steel, reinforced concrete and prestressed concrete tanks and containment vessels. Substantial improvements to these types of membrane structures are set out in U.S. Pat. Nos. 4,879,959; 5,134,830; 4,776,145; 5,094,044 issued to the subject inventor which are incorporated by reference, but which do not accomplish the advantages of the subject invention.
Another general category of existing tanks are those made of fiberglass. These fiberglass tanks have generally been small in diameter, for example, in contrast to the prestressed or steel tanks that can contain as many as 30 million gallons of fluid. The cylindrical walls are often filament-wound with glass rovings. To avoid strain corrosion, (a not very well understood condition wherein the resins and/or laminates fracture, disintegrate or otherwise weaken) the tension in fiberglass laminates is typically limited to 0.001 in/in (or 0.1%) strain by applicable building codes or standards and by recommended prudent construction techniques. For example, the American Water Works Association (AWWA) Standard for Thermosetting Fiberglass, Reinforced Plastic Tanks, Section 3.2.1.2 requires that "the allowable hoop strain of the tank wall shall not exceed 0.0010 in/in." A copy of this standard is provided in the concurrently filed Disclosure Statement. Adhering to this standard means, for example, that if the modulus of elasticity of the laminate is 1,000,000 psi, then the maximum design stress in tension should not exceed 1,000 psi (0.001×1,000,000). Consequently, large diameter fiberglass tanks have required substantially thicker walls than steel tanks. Considering that the cost of fiberglass tanks has been close to those of stainless steel, another common type of tank, and considering the above strain limitation, there are not believed to have been any viable large diameter fiberglass tanks built world-wide since fiberglass became available and entered the market some 35 years ago. Another reason why large fiberglass tanks have not been viable, is the difficulty of operating and constructing the tanks under field conditions, water tanks, for example are often built in deserts, mountaintops and away from the pristine and controlled conditions of the laboratory. Resins are commonly delivered with promoters and catalysts for a certain fixed temperature, normally room temperature. However, in the field, temperatures will vary substantially. Certainly, variations from 32° F. to 120° F. may be expected. These conditions mean that the percent of additives for promoting the resin and the percent of catalyst for the chemical reaction, which will vary widely under those temperature variations, need to be adjusted constantly for the existing air temperatures. Considering that these percentages are small compared to the volume of resin, accurate metering and mixing is required which presents a major hurdle to on-site construction of fiberglass tanks, The above problems have been remedied to a great extent by the teachings of the undersigned inventor's U.S. Pat. Nos. 4,879,856; 5,134,830; 4,884,747; 5,076,495 and 5,092,522 which are hereby incorporated by reference, and regarding which the subject patent represents a further evolution and improvement. There have also been problems with seismic anchoring of the above tanks, some of which have been solved by the techniques and apparatus disclosed in Mr. Dykman's U.S. Pat. Nos. 5,105,590 and 5,177,919, which are also hereby incorporated by reference.
SUMMARY OF INVENTION
In a first aspect of the present invention, a prestressed tank is disclosed, with the dome formed by first deploying or forming a membrane on a base, placing rigidifying material and/or prestressing or reinforcing on the membrane as needed, allowing the same to harden after it has been shaped in the form of a dome by the selective introduction of air between the floor and the membrane (forming in effect a preformed dome), constructing the walls of a tank upon the base and around said preformed dome, and then raising or floating the pre-formed dome on a cushion of air by the use of compressed air pumped under the membrane. After the dome is raised to a predetermined height, it. is then anchored to the walls of the tank.
In another aspect of the subject invention, these tanks, which can be constructed at relatively low cost and are suitable for most liquids in sizes to 50 million gallons (MG)--include an advanced hybrid construction of a prestressed concrete (PC) wall and dome design with a light-cured fiber reinforced plastic (FRP) lining (or membrane) covering the floor and the inside surface of the walls and dome. These tanks can also be constructed with a FRP-AL (aluminum) floating roof--with a prefabricated FRP dome--or with a reinforced concrete (RC) FRP-lined flat slab roof supported by FRP-RC columns.
In another embodiment, a separate dome or lid can be manufactured using this same process of forming a membrane, using air to shape the membrane into a dome, placing rigidifying material placed thereon and allowing the same to harden forming a composite structure.
In one aspect of the invention, the walls are a composition of fiber reinforced plastic, concrete, shotcrete, regular reinforcing steel and circumferential prestressing.
In another aspect of the invention an outer membrane is used to protect the above construction from the elements.
In yet another aspect of the invention exterior or interior insulation is used to compensate for large temperature gradients.
In another aspect of the present invention, seismic countermeasures or anchors are used to protect the contemplated structure against earthquakes and other tremors. To eliminate instability or possible rupture, the tank walls are anchored to the base through seismic cans. The cans are substantially oriented in a radial direction in relation to the center of the structure, permitting the seismic forces to be taken in share by the seismic anchors. The walls of the structure are free to move in or out in the radial direction allowing the structure to distort substantially into an oval shape thereby minimizing bending moments in the wall. Thus, when a seismic disturbance occurs, the force acting on the structure can be transmitted and distributed to the footing parallel to and around the circumference of the tank.
In another aspect of the present invention, a floating roof is used to minimize combustible vapor between the roof and the liquid which may be subject to explosion. Typical tanks of this type are gasoline and jet fuel tanks.
In yet another aspect of the invention, using more accurate analysis and construction means set forth by this invention, the thickness of the walls can be substantially reduced and more easily constructed. The automated means of construction recommended, the automated rotating tower apparatus and the floating roof concept can substantially facilitate construction and decrease the costs for a large variety of tanks for water, sewage, chemicals, petrochemicals and the like.
The invention described herein provides an excellent example of how combining the strengths of FRP and PC can be used to construct structures with increased usefulness, liquid tightness and corrosion resistance. Prestressed concrete excels in structural performance whereas FRP excels in liquid tightness and corrosion resistance. The combination enables one to build very large tanks for an almost unlimited range of liquids, faster and cheaper than heretofore possible. This development has been the culmination of 40 years of experience in tank design and construction covering some 2 billion gallons of storage and 8 years of intensive development work.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an elevation view of a circular domed roof composite structure, containment vessel or tank which forms part of the subject invention.
FIG. 2 shows a plan view of tank wall and wall-footing construction.
FIG. 3 shows a cross-section of the wall-floor-footing construction.
FIG. 4 shows a cross-section of the outer membrane and outer footing to which it is anchored.
FIG. 5 shows a typical wall section and partial view of the inside wall surface; also showing the seismic bars extended into the wall footing.
FIGS. 6A, 6B, and 6C show the dome in various stages of construction.
FIG. 6A shows the FRP floor membrane (100), which has been formed around the central column (118), with appropriate layers of rigidifying material laid thereon (135) before the setting of the same and before air has been introduced to shape it into the form of a dome.
FIG. 6B shows the membrane (100)/rigidifying material (135) composite structure after air has been used to shape it into a dome and after the rigidifying material has cured to create a preformed rigid roof. Air seals (106) between the roof (15) and the walls (104) are also shown to allow the dome to be raised or floated into its final position with air.
FIG. 6C shows the preformed dome roof (15) fastened in place near the top of the walls (104) after it was raised on a cushion of air and without the use of any scaffolding.
FIG. 7 shows a cross-section of a flat slab roof and column construction.
FIG. 8 shows a cross-section of a floating roof construction.
FIG. 9 shows a cross-section of wall and footing and a side view of the tank construction machinery required to build this new type of tank.
FIG. 10 shows the shear resistance pattern from the seismic anchors with the direction of seismic forces in the north-south direction.
FIG. 11 shows a typical tower which revolves around the periphery of the tank structure on wheels or similar means and which allows the prestressing, shotcreting, light curing and other machinery to be utilized to construct the tank.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an elevation of a dome-roofed tank of the type constructed utilizing the novel methods and materials disclosed herein. Simply, walls (104) are seen resting on a pad (10) and also serve to support roof (15). On the assumption that his is a liquid holding tank, the high liquid level is shown by dotted line (20).
FIGS. 2 shows a plan view on wall and walls footing. In FIG. 2, the walls (104) are cylindrical in nature and of FRP-PC construction. A monolithic FRP floor (100) or membrane is constructed on a one-inch thick cement mortar leveling pad (102) and partially on the wall footing (91). The floor (100) is made up of a liner or membrane formed, in the best mode, of four one-sixteenth inch thick layers of relatively flexible double-bias knit glass fabric impregnated with high elongation light curable vinyl ester resins which cover the entire floor area inside of the tank, the underside of the wall and portion of the wall footing. The floor membrane can also be made of other materials. Floor 100 is preferably placed on two layers of ten mil (10 mil) polyethylene sheeting which covers the concrete levelling pad (102) and wall-footing (91). This allows the walls to slide inwardly in a radial direction (such as when prestressing takes place or the liquid level changes) in a more efficient manner and prevents the FRP from sticking to the floor. The resins can be cured by conventional UV-light curing type lamps and by mechanisms as discussed in part in U.S. Pat. No. 5,094,044 to Mr. Dykmans which is incorporated herein by reference. The walls (generally shown by number 104) are likewise constructed with an inner liner (106) or membrane made up of four sheets of one-sixteenth inch thick double-biased knit fabric with high elongation-type light curable vinyl ester resins on the inside. A double seal is preferably made between the floor (100) and wall lining (106) by an approximately 18" wide splice lining (93) on the inside and (92) on the outside (covering the floor and the wall up to about 18")--again made from 4 layers of double-bias knit glass fabric impregnated with high elongation-type light curable vinyl ester. The inside corner of wall and floor is further strengthened with a FRP core of the same glass/vinyl/ester construction.
Turning now to the walls (104), as shown in FIG. 3, the floor lining (100), wall lining (106) and splice linings (93) form a combined membrane which is the inner layer of the tank. Outside this inner membrane--which lines the inside of the walls (106)--are layers of shotcrete, reinforcing steel and wrapping composite wall (104) (FIG. 3). Brochure 1293 entitled "Typical P.C. Machinery and Tanks" included in the Disclosure Statement and incorporated herein by reference shows the shotcreting in progress. More specifically shown in FIG. 51 this composite wall (104) consists of layers of shotcrete 104A, wrapped wire 104B and vertical reinforcing bars 104C. As also shown in FIG. 6C, the prestressed wrapping material (104B) used to prestress the walls (104) may initially be 5 mm diameter hot dipped galvanized high tensile wire. Other material which may be used is 5 mm (0.196") S-2 glass wire--wound on specially designed reels of 8 ft in diameter constructed to accommodate 65,000 feet of material per reel. Other types of prestressing, of course, can also be used.
We turn now to a description of prestressing machinery. That machinery--shown in FIG. 9 (commercially to be called the DYK 6)--consists of a motorized revolving tower (112) and a radial truss (114) which supports the radially rolling overhead carriage (122). A prototype of the DYK 6 machine may be seen in DYK-TECH's brochure 1293 entitled "Typical PC Machinery and Tanks" included in the Disclosure Statement and incorporated herein by reference. Radial truss (114) is connected on one side to revolving tower (112) and on the other side to a swivel (116) in the center of the tank which is supported by a cylindrical center tower (118) bolted to a 10 ft or larger diameter reinforced concrete slab (120). Carriage (122) moves in or out radially on the truss and is controlled electronically. Attached to the outside of this carriage (122) are extendible vertical posts (124 and 126)--driven up or down by electric motors--which are electronically controlled for their up or down movements. The swivel (116) permits simultaneous conveyance of concrete, mortar, water and compressed air by placing, compacting and finishing apparatus mounted on posts (124) and (126). Mounted on top of rolling tower (112) is a diesel driven generator (113) to provide power for light curing and electric motors. Inside the rolling tower is a wire wrapping assembly (122A) (such as that shown in U.S. Pat. Nos. 3,572,596; 4,302,978; 3,504,474; 3,666,189; 3,892,367 and 3,666,190 and in the 2-page color brochure No. 1293 entitled "Typical PC Machinery and Tanks" included in the Disclosure Statement and which are incorporated herein by reference.) Outside the tower (112) is a nozzle assembly such as that shown in brochure No. 1293 above but not shown in FIG. 9, which are electronically controlled as to raising and lowering. The rolling tower is supported by hydraulic wheel motors, the rotation of which are also electronically controlled, which cause the tower to roll around the tank and used, for example, in shotcrete applications, wire wrapping, light curing and concrete placement of the roof.
Turning now to the foundation, as illustrated in FIG. 3, the construction of the tank starts with preparing the pad or foundation starting with a compacted subgrade--meeting freeway subgrade standards--followed by the construction of a concrete footing (91), concrete leveling pad (102); and, as illustrated in FIGS. 6A, 6B and 9, a thickened center concrete slab (120) 10 ft in diameter (or larger), to support the center tower (118), which in turn supports the radial truss (114) and carriage (122) used for performing operations on the roof. FIG. 4 illustrates a typical outer footing 91A, to which is anchored an outer inflated membrane 106A which is used to protect and shield the construction of the tank from the elements. See U.S. Pat. Nos. 4,884,747, 4,879,959 which are incorporated herein by reference and also describe such outer membrane.
We now describe construction of the FRP floor. As shown in FIGS. 3 and 6A, the completion of the foundation is followed by the installation of the 1/4" thick FRP floor (100) which, in the best mode, consists of 4 layers of light curable prepregs--reinforced with biaxial glass matt--which typically are delivered to the jobsite rolled up (carpet like) in a black polyethylene cover to prevent premature curing by daylight. While conventional FRP is cured by combining resins with promoters and catalysts, light cured resins are cured by UV (ultraviolet) rays available in sunlight and special conventional heatlamps such as used for skin tanning. These are then rolled out in continuous layers--for example, side by side in a North-South direction--with overlapping joints, and subsequent layers always retaining the top black polyethylene cover, until the next layer of prepregs is placed. The first layer of prepregs will have a black polyethylene cover on both sides to prevent, for example, the FRP from sticking to the concrete floor and footing and to facilitate the relatively small radial wall movements thereby tending to preserve the integrity of the wall-floor connection during; i.e., circumferential prestressing and fluctuating water depths. Upon completion of the rolling out of these "carpets", the prepregs are cut circumferentially to the desired radius followed by light curing. (See U.S. Pat. No. 5,094,044 issued to the subject inventor and application Ser. No. 08,076,261 filed Jun. 11, 1993 by the subject inventor, and information in the Disclosure Statement which are all incorporated herein by reference.) After the floor (100) of the tank has been light cured--generally within 24 hours--as shown in FIG. 6A, a second 1/4" thick FRP layer or membrane (134) will be constructed--and light cured--on top of the FRP floor lining 100. What will become the inside liner of the dome (15), is constructed in the same manner as the floor (100) which was detailed earlier.
We now discuss the installation of the prestressing machinery. As shown in FIG. 6A, a center hole--somewhat larger than the outside diameter of the round center tower support 118--is then cut out of the two FRP linings (for both the floor (100) and the dome (15)) after which the center tower (118)--which supports the swivel (116)--is erected and bolted down to the 10 ft diameter reinforced concrete tower support slab (120), followed by the raising of the external rolling tower (112) which revolves on a circular pathway outside of what will be the walls. This is also shown in FIG. 11 and disclosed in U.S. Pat. No. 3,572,596 issued to the subject inventor. Radial truss (114) is then installed spanning tower (112) and center tower (118). Installation of the remaining components of the prestressing (DYK 6) machinery then follows. Brochure 1293 entitled "Typical PC Machinery and Tanks" authored by Mr. Dykmans and attached to the Disclosure Statement shows the prototype of this DYK 6 machine.
Construction of the FRP-PC dome can now take place. Simultaneous with the erection of the prestressing (DYK 6) machinery, work proceeds on the installation of the dome reinforcing (136) (see FIG. 6C) and concrete (135) (see FIGS. 6A & 6B) upon the dome lining (134).
Upon completion of the installation of the reinforcing steel (135), the concrete (136) is placed upon the dome lining 134, vibrated and screened in one continuous process--aided by conventional screeds and vibrators attached to posts 124 (2 each) and 126 (2 each) positioned on either side of carriage (122) on the radial truss (114), on the revolving DYK 6 machine (see FIG. 9). Concrete placement is facilitated by the system's ability to pump concrete through the swivel (116) to the discharge point on one of the leading post (126) adjacent to the carriage (122). The other posts (124) and (126) can be used to facilitate vibrating, screening and floating of the concrete. A retarding agent can be added to the concrete to sufficiently delay the concrete "set-up" time--which is the starting point of the concrete hardening process to allow the "inflation" of the membrane to create the dome. The FRP liner, when cured is an inflatable or flexible membrane capable of stretching and inflation. The inflation of the membrane and concrete thereon (shown in FIG. 6B) is accomplished with compressed air introduced by conventional means (not shown) between the dome membrane (134) and floor membrane (100)--until the slab has become a substantially spherical dome shell of the desired rise (See FIG. 6B). The concrete will then be re-vibrated, screeded and floated with the aid of the revolving DYK 6 machinery shown in FIG. 9. (See FIG. 6B) Where necessary the periphery of the membrane may be thickened or weighed to hold the edges of the dome membrane down, whereas the center is free to move up during the inflation process, to arrive at the desired shape of the dome.
Once the dome membrane (100) and concrete composite (135) has been raised to the desired shape, the dome concrete is now permitted to harden into what may be called a pre-fab dome structure as shown in FIG. 6B. Whereas smaller domes may have sufficient reinforcing without the need for additional circumferential prestressing, larger domes will require circumferential prestressing of the dome ring which may be done, for example, with FRP tape wrapping (140, see FIG. 6B), wound wire, or other prestressing material before the wall construction is started.
We now turn to the embodiment in FIG. 7, depicting a flat slab roof supported by columns. As with the dome-shaped roof, the work will start by constructing the FRP membrane on the floor (explained previously)--followed by cutting the center hole--the erection of the center support tower (118) and then the assembly of the rest of the (DYK 6) prestressing machinery. During erection of the (DYK 6) prestressing machinery, 1" thick FRP column location pads (119) are glued to the FRP floor lining (100)--followed by the installation of FRP column-roof connector rings (121)--the erection of the FRP column tubings or sleeves (142)--the gluing of the re-bar support blocks (123) (which also serve as FRP anchors to the concrete)--the installation of the reinforcing steel (122), and the pouring, screeding, vibrating and finishing of the concrete with the DYK 6 prestressing machine. The FRP column tubings (142)--which can be furnished in any transportable length in diameters to 16", are then plumbed, braced and then filled with reinforcing steel and concrete. They will harden into rigid columns (119a)
The subject invention contemplates a variety of roofs including a floating roof as shown in FIG. 8. The construction procedure of these roofs is similar to the flat slab roof of FIG. 7. The floating roof would have a PRP lining (147) enclosing a light-weight core 150. A double spring-loaded Teflon-coated neoprene seal (148) is used to contain liquid emissions and rain water which will be drained off through flexible hoses connected between the discharge points on the roof and the drain pipes coming through the floor.
The invention also contemplates using prefabricated FRP roofs of the type illustrated schematically in FIG. 8. Roof 143 is shown in phantom. These roofs would be trucked in and installed after the wall has been completed.
After the floor and dome have been constructed, attention will be given to building the walls of the tank. In a preferred embodiment as shown in FIG. 1, rigid prefabricated FRP wall forms (30) are first constructed. Preferably, they are 8 ft wide by 40 to 50 ft long and are extendible for greater liquid heights and adjustable for the desired wall radius. These wall forms will then be erected and braced to anchors in the concrete dome or flat slab concrete roof while they are still on the floor. The 1/4" thick FRP wall membrane is constructed in a similar manner as the floor membrane except that the rolled-up "carpets" will be attached to the form at the top and rolled down to the footing. The wall membrane will then be light-cured in a spirally upward or downward motion around the tank with a bank of UV emitting lights--attached to the spray escalator on the DYK 6 machine.
Seismic anchors can be integrally constructed with the walls. Turning to FIG. 3 (and as also illustrated in the publication "the DYK 6 concept" provided with the Disclosure Statement), the connection utilizing seismic bars (154) does indeed reduce bending stresses in the wall as discussed earlier. These rectangular stainless steel bars (154) are solidly encased in the wall and are positioned in rectangular stainless steel cans (156) cast in the concrete footing. A close fit between the bars (154) and the radial walls of these cans (156) constrains these bars to be essentially prevented from moving circumferentially. (FIG. 10) On the other hand, there is ample room in these cans (156) to permit the bars (154) to slide freely in the radial direction inside these cans (156).
For example, let one assume that seismic forces, are acting in the North-South direction. (See FIG. 10) Each N-S force acting on these bars is essentially the resultant of 2 forces: one radial and one circumferential. The radial components are the ones typically creating the vertical bending moments in the wall, so the goal is to minimize these radial forces. This is accomplished by permitting the seismic bars (154) to move freely in the radial direction. That leaves the circumferential component to contend with. As shown in FIG. 10, the magnitude of these circumferential forces change with either the sine or the cosine of the angle between the radial direction of these cans and the N-S line or the E-W line. See U.S. Pat. Nos. 5,177,919 and 5,105,590 on the subject issued to the subject inventor and incorporated herein by reference. Thus, for a N-S seismic direction load--the maximum circumferential forces develop on the true East and West points gradually reducing to zero at the true North and South points. The sum of all the North-South components on these bars equal the seismic force acting on the tank.
We now turn to FIGS. 3 and 5, to analyze the wall construction upon completion of the FRP floor (100), vertical re-bar supports (105) (See FIG. 5) will be attached to the FRP lining (106) which can be shaped in a manner that they will also serve as mechanical anchors of the lining to the wall. This will, be followed by installation of multiple layers of vertical re-bars (104C), pneumatic mortar (104A) and wire wrapping (104B). (See FIG. 5) The pneumatic mortar application is a continuous process, accomplished by the (DYK 6 Machinery revolving around the perimeter of the structure similarly as shown in brochure 1293. The material is applied in a spiral motion--either going up or down by apparatus contained in the carriage 122 which for this purpose is raised and lowered on the outside of rolling tower 112. Mortar and compressed air is pumped by conventional means from the ready mix truck (also shown in brochure 1293) and compressor (not shown-adjacent the ready mix truck) through separate hose lines which are run, first under the floor and then come up through the circular center slab, up the central tower 118, through the swivel (116) (see FIG. 9)--then moving radially on radial truss 114 to the vertical tower (112) where they connect to the nozzle on the spray escalator 122B. In cold regions of Canada and Alaska or where necessary polyurethane insulation can be sprayed on the exterior wall surface to minimize the differential temperature effect. Likewise, a barrier of polyurethane insulation can be installed between the inside wall membrane and the wall composite when hot liquids will be stored inside the tank. Another way to overcome large temperature differentials would be to bury the tank in the ground.
Stripping of the wall forms can start before the wall construction has been completed after sufficient wall thickness has been built up to withstand wind pressures without the assistance of the form support.
After the walls have been constructed, the stage is set for raising of the dome--or flat roof--with compressed air to its final position. This will start immediately after the circular wall (104) has been completed. In a preferred embodiment, to avoid ripping of the roof, the air pressure will be kept somewhat below what is needed to raise the roof. The remainder force may be provided by a series of small winches placed at equal distances around the circumference of the roof and at each column. They will be regulated in a manner that the roof will be raised evenly in a controlled manner. In its final position, support brackets (152) (see FIG. 6C and 7) will be installed and a FRP closure connection (107) is made between the upper wall lining and the FRP inside roof lining. In one embodiment, the flat roof (105) (see FIG. 7) is further supported by stainless steel support plates (153)--resting on FRP seal plates on top of the columns--which are bolted to anchor bolts in the concrete slab of flat roof (105), around each column. Subsequently the air pressure is released.
A pre-fabricated FRP ventilator (not shown) may then be installed after the center tower (118) has been removed. At the same time the center hole in the floor is closed with a FRP plate adequately overlapping the floor while appropriate connections being made to accommodate protruding pipe.
FRP staircases or ladders can then be attached to the outside wall surface. Flanged pipe nipples for inside or outside pipe connections can be installed in the wall or dome. Whenever possible it would be better to install all supply, discharge, scour, overflow and redundant pipes (for possible future use) under the floor--entering the tank floor in pre-planned locations--preferably--where possible--in the center slab area of the tank.
In another preferred embodiment, the tank may be analyzed 3-dimensionally with a finite element program. In the structural analysis, the wall cylinder and the dome shell are considered a composite consisting of layers of concrete, steel and FRP as detailed in the right hand bottom corner of photos 1 to 16 of the Dyk 6 Concept color brochure filed with the Disclosure Statement. Each layer of this composite can be analyzed for the stresses and deformations developed in that layer which can be presented graphically and in color in the form of stress contours and deformation curves including pin pointed locations of the maximum and minimum stresses, which is depicted in preliminary form in the Dyk 6 Concept brochure.
The tank analysis may consider the following stress and deformation causing conditions--including buckling--for tank empty and tank full conditions:
1. prestressing during and after wrapping;
2. internal liquid loads--static and dynamic (seismic);
3. uniform and asymmetrical backfill pressures on the wall--static and dynamic;
4. snow and other roof live loads--static and dynamic;
5. wind loads on roof and wall--both pressure and suction;
6. differential summer temperatures--aggravated by differential sun temperatures;
7. differential winter temperatures.
Again, the referenced Dyk 6 Concept brochure (See Disclosure Statement), shows, in color, the maximum, shotcrete compression in the wall without consideration of temperature differential conditions in contrast when winter temperature and snow loads are taken into account. Note the difference in compression of 925 psi versus 1,345 psi. This brochure also shows the result of no summer differential temperature allowance. Compare the steel tension in the wall with that in photo 4 where summer differential temperature has been allowed. Note the difference in steel tension of 10,472 psi versus 20,881 psi. Summarizing the brochure, which because it is in color might be more informative than the drawings, photo 5 shows a compressive stress of 423 psi in the dome without summer temperature differentials whereas photo 6 shows a compressive stress of 1,345 psi when differential temperatures--sun included--are allowed for. Photo 7 shows a steel tension of 12,780 psi if no winter temperature differential has been allowed whereas photo 8 shows a steel tension of 21,760 psi when winter temperature differential and snow loads are allowed for. Photo 9 shows the wall buckling factor of 12.07 when no temperature differential has been allowed whereas photo 10 shows a buckling factor of 2.2. for summer differential temperature--sun included--has been allowed whereas photo 11 shows a buckling factor of 2.1 when winter differential temperature and snow load have been allowed. A buckling factor of 2 essentially means a safety factor of 2. Photo 12 shows the differential surface temperatures generated by the sun on dome and wall.
Also, for example with regard to seismic disturbances, the walls of the structure are free to move in or out in the radial direction allowing the structure to distort substantially into an oval shape thereby minimizing bending moments in the wall. This effect may be seen in photos 13, 14, 15 and 16 of the Dyk 6 Concept brochure. In photos 13 and 15, the "Base Restraint is Radial--Free and Circumferential-Locked." In photos 14 and 16, the "Base Restraint is Radial-Locked after full prestress and Circumferential-Locked." The difference in steel stress is 20405 psi in photo 13 and 34,224 psi in photo 14. The difference in shotcrete compression is 260 psi in photo 15 and 1,382 psi in photo 16. Thus, when a seismic disturbance occurs, the force acting on the structure can be designed to be transmitted and distributed to the footing parallel to and around the circumference of the tank.
A sun temperature--applied at right angles to the surface--can be assigned a certain value over and above the air temperature. A realistic figure would be 50 D.F. This assumption was used in the case of photo 12 in the Dyk 6 Concept brochure reference the yellow letters in the white border line area in the top left area of the photo. If the sun position to that surface is less than 90 degrees, one could use the sine value of the angle between the sun and the surface under consideration. The analysis of the tank takes into account the direction of the sun to the vertical line of tank revolution (see photo 12 upper middle area), the N-S-E-W coordinates and the relative angle of the sun to each wall, roof or floor element--whether the sun shines on the outside surface of covered tanks or on the inside and outside surface of open top tanks. Furthermore--since concrete cannot take tensile stresses--they are automatically zeroed out when they develop at any point to insure true tensile stresses in the reinforcing steel. Page 1 of brochure 0794, attached to the Disclosure Statement, offers attractive cost data and construction times for 50 year rated open top and fixed dome roof tanks. Reference the comparisons on page 2 of brochure 0794, these costs do not only compare favorably with carbon steel tanks--they are also substantially lower than RC and PC tanks.
Thus, an improved dome structure is disclosed. While the embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention therefore is not to be restricted except in the spirit of the appended claims. | The present invention is directed to improved tank or containment vessels and processes and apparatus for their construction. The tanks or containment vessels usually consist of circular walls resting on a base and a dome supported by the walls. The dome of the subject prestressed tank is formed by deploying or creating a membrane on the base, applying one or more layers of rigidifying material (and prestressing or reinforcing material if needed) on the membrane and then forming said membrane into a dome before the rigidifying material sets by the selective introduction of compressed air at appropriate locations between the base and the membrane. The hardening of the rigidifying material results in a composite preformed rigid roof or dome having a membrane liner and an overlay of composite construction. Once the walls are created, air pressure can be further utilized to raise this preformed composite dome upward to a predetermined height after which it is fastened to the walls. An appropriate air seal may be used to prevent excessive leakage of air between the walls and the dome and to assist in the raising of the dome. Utilizing this air cushion procedure to raise the dome to its proper location, eliminates the need of scaffolding and other costly support structures. Integral seismic anchors may be also used to complete the construction process to protect the structure against earthquakes and other tremors by anchoring the dome to the tank walls and the tank walls to the base in a manner whereby the seismic forces are translated parallel to the wall instead of radially to the wall. | 4 |
TECHNICAL FIELD
[0001] This application relates generally to computer networks and more particular to a system for electronic commerce.
BACKGROUND
[0002] Electronic commerce has grown rapidly in recent years and now is fundamental to the world economy. The ability to effectively target consumers in this medium is therefore increasingly important to businesses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 illustrates an example functional block diagram of an online system for placement and monitoring of online advertising.
[0004] FIGS. 2-5 illustrate example flow charts for setting up accounts, creating campaigns and selecting offers from those campaigns among advertisers and Influencers.
[0005] FIGS. 6A , 6 B, 7 and 8 illustrate example methods for creating tags and matching tags between Influencers and advertisers.
[0006] FIG. 9 illustrates an example method for creating an Influencer Quotient for an Influencer.
[0007] FIGS. 10 through 22 illustrate various example processes and functions used by Influencers, and end viewers.
[0008] FIG. 23 illustrates an example of different configurations of Widgets available to an Influencer.
[0009] FIG. 24 illustrates commenting and feedback on offers by Influencers.
[0010] FIG. 25 a method of aggregating comments from FIG. 25 and analyzing the breakdown of the user feedback as well as reporting the data to Advertisers in various forms.
[0011] FIG. 26 illustrates an automated method of setting up offers without human intervention.
[0012] FIG. 27 illustrates a user's ability to select between better offers or a larger quantity of offers, based on their preferences.
[0013] FIG. 28 illustrates a system according to an example embodiment of the present invention.
[0014] FIG. 29 illustrates a block diagram of a machine in the example form of a computer system within which a set of instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed.
DETAILED DESCRIPTION
[0015] In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings which form a part hereof, and in which is shown, by way of illustration, specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical, electrical, and other changes may be made without departing from the scope of the present invention.
[0016] According to one example embodiment, the system described herein supports online marketing programs designed to leverage the power of peer-recommendations to promote actions desired by advertisers. The system provides that influential bloggers, website operators, and social networker users (collectively called Influencers) can review, select and recommend pre-screened, valuable offers from advertisers for their friends and viewers (Viewers). Using Widget and tagging technologies, the system allows advertisers to direct their offers to the Influencers where Viewers are in the target market. Influencers with the largest communities or communities that generate the best “take rates” may, in one example embodiment, receive a higher “The Influencer Quotient (IQ)” than Influencers with smaller communities and lower “take rates”. The IQ is a value that may represent the combination of community size and community responsiveness. The Influencers with the highest IQ scores may, in one example embodiment, receive the right to view and select from advertisers' most valuable offers. In another example embodiment, Influencers use their IQ to select offers whose sum IQ value is equal to or less than that of the Influencer's IQ.
[0017] The system, thus, can create a virtuous-circle. Influencers who are able to offer their communities the most valuable advertiser-offers will likely see their online reputations or status enhanced and their Viewer communities grow. Influencer's IQ score will increase and as a result, they will receive the right to view and select even more valuable offers for their Viewers.
[0018] Thus, using the system described herein, advertisers can follow the trail of blogs and social networking sites to find and recruit customers all over the world through peer endorsements.
[0019] Unlike traditional keyword advertising, the Influencers may, in some embodiments, have say over which ads and offers are shown to their Viewers and which are not. The preexisting loyalty between the Influencer and his or her Viewers may make the message more powerful for the consumer and more effective for the advertiser.
[0020] Unlike traditional advertising, Influencers may, in some embodiments, be allowed to add comments (e.g., FIG. 24 ) and their own text to offers they provide to their end viewer audience. These comments may be displayed to end viewers and they may be aggregated and analyzed for advertisers.
[0021] As used herein, the term “Influencer” is an individual who publishes messages with a personal viewpoint or opinion, wherein the message are published on a web page, website or other Internet-accessible medium, and wherein the individual has a following or audience that is influenced by the messages. The messages may include text or pictorial or other forms of communication. The Influencer may be identified by his or her real name or a pseudonym. An Influencer may be, for example a person who publishes messages on a website, including a blogger, social network participant or other website owner. The Influencer may draw many viewers to their web pages or website and influence a large number of viewers, or a small number of viewers. A “Widget” is an external component of a website which displays to viewers. “Tags” are a brief text description of a concept, generally an adjective or a noun, alternatively referred to as keywords. A “Tag Cloud” is a collection of tags that represent a larger concept—such as an Influencer or an Advertiser offer. An “Offer” is a component of a campaign, generally taking the form of a discount, promotion or ad. A “Campaign” is either a single offer or a collection of related offers.
[0022] Referring now to FIG. 1 , there is illustrated a functional block diagram of a first example embodiment of an online advertisement system according to the inventive subject matter described herein. An offer and rewards engine 110 works in conjunction with a database server 120 to provide a website 125 to support an online ad placement service. A plurality of advertising administration functions 130 , advertiser functions 140 , Influencer functions 150 and Widget functions 160 are provided.
[0023] FIG. 2 illustrates an example flow chart 200 for setting up an Influencer account using the Influencer functions 150 . As illustrated, the Influencer may enter 202 the website 125 where the requirements for signing up may be checked. The user may join 204 the ad placement service in which case they enter basic contact and demographic information. The Influencer then may disclose 206 to the service his or her content as may, for example, be on the Influencer's website, web page(s) and/or blog. The website 125 may also be set to crawl the Influencer's website to determine key words and content of the Influencer's site. The Influencer may then select a Widget 208 , for example, by color, size, content and layout. The Widget may be installed 210 on the Influencer's website or page(s), either manually or automatically. The Influencer may also select 212 a preliminary set of offers for his or her community to view, through the installed Widget. This finishes 214 the Influencer's sign up, Widget installation and ad selection process.
[0024] FIG. 3 illustrates an example flow chart 300 for advertisers to sign up for the ad placement service. The advertiser may enter 302 the site 125 , create an account 304 , authorize administrators and users 306 , set up billing information 308 , and reviews and approves 310 of the advertiser account.
[0025] FIG. 4 illustrates an example flow chart 400 wherein an advertiser can set up a campaign/offer. An authorized advertiser representative enters 402 the website 125 . A campaign may be set up 404 , including setting a campaign budget, a campaign type and user tracking and identification. Offer set up 406 may include setting the text of offers, artwork, budget, value of the offers, redemption instructions and tag instructions. Campaign billing information may also be entered 408 , wherein the campaign billing limit may be set and the payment method selected. New offers may be submitted 410 and may or may not require approval by website 125 personnel. New campaigns and offers may then be launched 412 .
[0026] FIG. 5 illustrates an example flow chart 500 of an advertiser entering 502 an ad placement website 125 and reviewing campaign/offer performance 504 reports, including which campaigns/offers are in progress, the budget/spending for them, performance by individual Influencers, and details of any given Influencer. The advertiser may create 506 customized reports, perform “what if” analyses 508 and refine campaigns/offers 510 as required.
[0027] According to one example embodiment, as illustrated in FIG. 6A , the tags between the Advertiser's campaign may be compared by server 120 with each Advertising Influencer. Users with a high overlap in tags are considered good candidates for a campaign. Influencers with low or no overlap in tags are not good candidates for a campaign.
[0028] After a preliminary group of Influencers have been identified by tag matching, the system then may remove the influencers who do not have a sufficient IQ to show the offers to their communities.
[0029] After qualified Influencers are identified, they are offered the campaign in the account profile section of Advertising.
[0030] As illustrate in FIG. 6B , multiple offers may be created. This may be done by duplicating the offer tagging clouds and ad content. Matches may be identified between tagging clouds, for example using fuzzy logic to determine an overlap between advertiser tags and Influencer tags.
[0031] According to one example embodiment shown in FIG. 7 , Influencers may describe their site to advertisers using tags. These tags help identify both the content of the site as well as the demographics and psychographics of the reader base. According to one example approach, three elements may make up the Influencer's Tag Cloud: Users self Tagging, Tags from the scraper, and tags from 3rd party sites (e.g., Technorati, Digg, etc.) These tags may not be weighted evenly. For example, user tags may take precedence and tags from the scraper may take the least priority.
[0032] According to another example embodiment illustrated in FIG. 8 , like Influencers, advertisers may describe their offer using a tagging cloud. Each offer is unique and thus, each offer has its own tag cloud. The primary source for offer tags is the Advertiser. Additionally, common product types may have a generic set of tags and Website.com may suggest related tags. These tags may be aggregated into the Advertiser Offer Tag Cloud.
[0033] As illustrated in FIG. 9 , The Influencer Quotient is a numeric value that represents how much influence the Influencer has and how large their audience is. An Influencer with a smaller, devoted reader base can still have a high IQ. An Influencer with a large reader base but less devoted fans may not have as high of an IQ as the example above.
[0034] Also, in this example embodiment, the Influencer Quotient is used to limit what ads an Influencer can see. For example, if an Influencer has an IQ of 5, he will not be able to display an offer that requires and IQ of 7. The IQ allows the advertisers to select between “better” Influencers or a wider audience. Influencers use the IQ to see their peer ranking and provide incentive to select offers their community uses to increase their IQ. The Influencer Quotient may be determined in any way desired.
[0035] Referring now to FIG. 10 , there is illustrated an example overall process flow wherein the various parties to an advertising transaction use the website 125 and the advertising service to place ads and earn ad placement fees and rewards. The following steps are illustrated in FIG. 10 :
[0036] Step 1: End Viewers visit Influencer's website.
[0037] Step 2: Then Influencer's website loads, it will also call code from the Website server
[0038] Step 3: Website will generate and provide the Influencer's website the contents for a Widget
[0039] Step 4: The Influencer's webpage, including the Website Widget will display selected offers and specials to the end viewer
[0040] Step 5: Since the Website Widget is coming from Website.com, the inventive subject matter captures HTTP Header information, cookies, and other information from the End Viewers.
[0041] Referring now to diagram 1100 in FIG. 11 , it is illustrated how the website 125 may provide an advertising portal 1102 , an Influencer portal 1104 and a website administration portal 1106 .
[0042] Referring now to the diagram 1200 of FIG. 12 , there is illustrated an example process for using the system and method of the inventive subject matter wherein an advertiser begins 1202 by setting up a campaign and its offers. The campaign is placed on the website 125 for Influencers to select 1204 . Qualified Influencers may select 1206 the campaign/offer for their website/web page(s). If the Influencer has not yet placed a Widget on their site, he/she may do so at this time 1208 . Viewers then see 1210 the Widget (served by the website 125 server) on the Influencer's site/page(s). The actions of viewers viewing or interacting with the Widget may be logged by the website 125 using the Widget. The website 125 may aggregate the data on usage, redemptions, views and clicks and generate a report for advertisers 1212 . Advertisers can view and track campaign success 1214 .
[0043] FIG. 13 to FIG. 20 illustrate various additional details of advertisers, Influencers and end users interacting with the website 125 to perform various tasks and functions and to take advantage of the service and system provided thereby. FIGS. 13 and 14 illustrate example functions and process 1300 and 1400 , respectively, used by an advertiser to administer their account and set up and administer campaigns and offers that can be offered to Influencers. FIG. 1500 illustrates example functions and process 1500 used by an Influencer to establish an account and privileges to run offers. FIGS. 16 and 17 illustrate example functions and process 1600 and 1700 , respectively, performed by an Influencer to select offers to present to his or her end viewers and to have those offers displayed by a widget on the Influencer's website. FIG. 18 illustrates example functions and processes 1800 used to present an offer to an end viewer using a widget and for the end viewer to select the offer and execute it if desired, for example by clicking on it and performing additional data entry steps.
[0044] FIG. 19 illustrates an example screen display to be used by an advertiser to enter an offer, wherein the number of Influencers qualifying to run the offer is displayed 1902 based on the tags entered by the advertiser for the offer.
[0045] According to one example embodiment illustrated in FIG. 20 , a screen display of website 125 may illustrate how an advertiser may view a report generated by the website to determine, for example, the percentage or number 2002 of Influencers running or not running a campaign or offer extended by the advertiser. Click through rates, impressions, conversions and cost per conversion 2004 may also be tracked.
[0046] FIG. 21 illustrates a sample screen display 2100 for an Influencer offer selection screen in website 125 . The screen shows the Influencer's Influencer Quotient, number of website points, and peer ranking. Offers 2102 may be selected. Also, some offers 2104 may not be available to be selected because the Influencer's Influencer Quotient is not high enough to gain access to the offers. In this way, for example, the Influencer is encouraged to obtain a higher Influencer Quotient. Widgets may be previewed in the left hand lower corner 2106 .
[0047] According to another example embodiment, the Influencer is offered rewards for selecting offers and successfully obtaining takers for those offers. FIG. 22 illustrates an example screen display showing the number of points earned for each offer 2202 and the total points. At the bottom of the screen is a viewing area 2204 to show gifts or rewards the Influencer can purchase with the earned reward points.
[0048] According to one example embodiment shown in FIG. 23 , a variety of Widget configurations may be offered to Influencers, such as vertical Widgets 2302 , or horizontal Widgets 2304 or 2306 .
[0049] According to one example embodiment 2400 shown in FIG. 24 , Influencers may be able to place comments, text or other messages 2402 in, on, or near the actual offers 2404 they have selected. Those comments, text or other messages 2402 may be displayed adjacent an offer 2404 when it is displayed using a widget on the Influencer's site. In one embodiment, to add comments, the user may click on an icon to the left of the selected offers 2404 and add comments in a process 2410 that results in the comments being stored on the server 120 and ultimately adjacent an offer in the display presented to an end-viewer using a widget.
[0050] According to one example embodiment 2500 shown in FIG. 25 , comments 2502 from all influencers may be aggregated 2504 and stored for analysis. These comments may be analyzed for general tone, positive/negative messages, length or other metrics. This can be done using human input or the server may use fuzzy logic 2506 . These comments may be analyzed and the results provided 2508 to an Advertiser on a per-offer or per-campaign basis 2510 . The full text of the comments may also be available to the Advertiser 2512 .
[0051] According to one example embodiment of the inventive subject matter, Influencers and advertisers are matched using various approaches, including searches on demographics or other parameters other than or in combination with demographics. One approach as noted above is such that after an advertiser sets up a new campaign, the advertiser assigns the campaign “tags” which will best reach their audience. Website 125 may return the possible number of Influencers and audience size based on historical data, wherein fuzzy matches may be used, such as “nerd”=“geek”. Advertisers will then be able to see sample Influencers based on the keywords they enter. Psychographics and interests will be used, for example, to help identify Influencers based on the tags entered by the advertiser.
[0052] According to another example embodiment, there may be three sources for Tags used. A preliminary set of tags will be generated based on content of the page and who links to the site. For example, a link from Slashdot will assign tags such as “technology” “society” “nerd.” A crawler will crawl the site and break down the content into major tags and keywords useful in identifying the content of the page. User-defined self-tags may also be used. Presumably, a user can identify their site and their audience better than a crawler or other non-human mechanism. These tags may take precedence over automatically assigned tags. They may be editable any time for the Influencer. Third party sites may also be referenced, such as tags from Digg, Reddit, StumbleUpon, etc. These tags may be used to provide an objective evaluation of sites.
[0053] Offers, in one example embodiment, may have comments attached by Influencers. Influencers may be free to leave any sort of comment with the possibility intent that they leave endorsements for a specific offer.
[0054] Further, according to one example embodiment, instead of Influencers only, any web-based proprietor may be offered an opportunity to sign up and select offers to offer to their readership. Accordingly, in this embodiment, the web-based proprietor need not espouse any personal viewpoints or opinions or have any following or audience as an Influencer may, but instead may simply have customers that visit the web-based proprietor's website or pages to access factual information or conduct commerce or for any other purpose. The web-based proprietor may, like Influencers described above, nonetheless characterize their end viewers and be offered offers to present to their end viewers to the same extent possible as Influencers.
[0055] In the above example embodiment, these comments may be analyzed by the inventive subject matter and reported to Advertisers. These comments may be used to help refine message strategies or to better target receptive audiences.
[0056] According to another example embodiment 26 , advertisers may not directly create offers for the subject matter. Content sources, such as established online retailers, may explicitly or unknowingly provide offers to the system described. The system may either explicitly take product information, through a data feed 2602 or the target site 2604 may be scraped and analyzed by the system 2606 . Offers are generated using an automated or semi-automated process 2608 and added to the offer queue 2610 for Influencers to select. Alternatively, a non-web system may be arranged where a content provider provides offers to Influencers through some other mechanism, electronic or offline 2612 .
[0057] In one example embodiment, as illustrated in FIG. 27 , users may choose between better offers or a larger quantity of offers 2702 based on their Influencer Quotient 2706 . In an embodiment, each offer is assigned an IQ value 2704 . Offer IQ's 2704 may be assigned based on product price, discount value, or other arbitrary measure. An influencer's IQ 2706 may allow them to select individual offers (e.g., 2708 , 2710 , 2712 , and 2714 ) that sum up to their IQ or lower. For example, if an influencer chooses sample offer 2708 with an IQ value of two and sample offer 2710 with an IQ value of two, the sum would be lower than the influencer's quotient of ten and thus allowed. However, if the influencer selects sample offer 2712 with an IQ of seven and same offer 2714 with an IQ of six, the sum would be greater then the allowed influencer quotient. Once an offer expires or is removed from the widget, the points it occupied may be recycled and may be used to select other offers.
[0058] According to another example embodiment, the user interactions may not take place on a website owed or operated by the Influencer. 3rd party websites may be used, such as social networks, to facilitate the user interactions or to allow quick adoption of the subject matter. In this potential embodiment, Influencers may use tools from their existing platform to install the subject matter.
[0059] FIG. 28 is a network diagram depicting a system 2800 , according to one example embodiment of the invention, using a client-server architecture. An online advertisement system 2808 (e.g., a network-based online advertisement system facilitating advertisements and offers between multiple influencers, viewers, and advertisers) provides server-side functionality via a network 2810 (e.g., the Internet) to one or more clients, such as a web client 2812 (e.g., a browser, such as the Internet Explorer browser developed by Microsoft Corporation of Redmond, Wash. or the FireFox browser provided by Mozilla Corporation of Mountain View, Calif., or a wireless browser, as is used in the case of certain cellular telephones). Communicatively coupled to the network 2810 is one or more of an advertiser machine 2802 , an influencer machine 2804 , and a viewer machine 2812 . Each of the machines 2802 , 2804 , and 2806 may further include (or provide access to) communications applications (e.g., email, instant messaging, text chat, or Voice over IP (VoIP) applications), enabling users of the online advertisement system 2808 to communicate.
[0060] An Application Program Interface (API) server 2814 and a web server 2816 may be coupled, and provide program and web interfaces respectively, to one or more application servers 2818 . The application servers 2818 may host one or more offer and reward applications 2820 and online ad placement applications 2822 . The application servers 2818 may, in turn, be coupled to one or more databases servers 2824 that facilitate access to one or more databases 2826 . The web client 2812 may access the offer and reward applications 2820 and online ad placement applications 2822 via the web interface supported by the web server 2816 .
[0061] Further, while the system 2800 shown in FIG. 28 employs a client-server architecture, embodiments of the invention are not limited to such, and may just as well utilize a distributed, or peer-to-peer, architecture. The various offer and reward applications 2820 and online ad placement applications 2822 may also be implemented as standalone software programs, with or without individual networking capabilities.
[0062] FIG. 29 shows a diagrammatic representation of a machine in the exemplary form of a computer system 2900 within which a set of instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed. In alternative embodiments, the machine operates as a standalone device or may be connected (e.g., networked) to other machines. In a networked deployment, the machine may operate in the capacity of a server or a client machine in server-client network environment, or as a peer machine in a peer-to-peer (or distributed) network environment. The machine may be a server computer, a client computer, a personal computer (PC), a tablet PC, a set-top box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a network router, switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein.
[0063] The exemplary computer system 2900 includes a processor 2902 (e.g., a central processing unit (CPU) a graphics processing unit (GPU) or both), a main memory 2904 and a static memory 2906 , which communicate with each other via a bus 2908 . The computer system 2900 may further include a video display unit 2910 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)). The computer system 2900 also includes an alphanumeric input device 2912 (e.g., a keyboard), a cursor control device 2914 (e.g., a mouse), a disk drive unit 2916 , a signal generation device 2918 (e.g., a speaker) and a network interface device 2920 .
[0064] The disk drive unit 2916 includes a machine-readable medium 2922 on which is stored one or more sets of instructions (e.g., software 2924 ) embodying any one or more of the methodologies or functions described herein. The software 2924 may also reside, completely or at least partially, within the main memory 2904 and/or within the processor 2902 during execution thereof by the computer system 2900 , the main memory 2904 and the processor 2902 also constituting machine-readable media. The software 2924 may further be transmitted or received over a network 2926 via the network interface device 2920 .
[0065] While the machine-readable medium 2922 is shown in an exemplary embodiment to be a single medium, the term “machine-readable medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable medium” shall also be taken to include any medium that is capable of storing, encoding or carrying a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present invention. The term “machine-readable medium” shall accordingly be taken to include, but not be limited to, solid-state memories, optical and magnetic media, and carrier wave signals.
[0066] Thus, as described herein, according to one example embodiment, the system described herein supports online marketing programs designed to leverage the power of peer-recommendations to promote actions desired by advertisers. The system thus may create a virtuous-circle, since Influencers that are able to offer their communities the most valuable advertiser-offers will likely see their reputations enhanced and their Viewer communities grow. Their IQ score will increase and as a result, they will receive the right to view and select even more valuable offers for their Viewers. Thus, using the system described herein, advertisers may follow the trail of blogs and social networking sites to find and recruit customers all over the world.
[0067] According to other alternative embodiments, any of the systems and methods described herein above, or as set forth in the accompanying claims, may further be embodied as a computer-readable product or article of manufacture wherein instructions may be tangibly embodied to perform the systems and methods described.
[0068] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | A system that utilizes peer influences to help advertisers to reach target audiences. This system used peer recommendations through Widgets and comments to influence consumer behavior. This is a system for placing advertising on Influencer websites or pages includes determining the audience of the Influencer and setting tags to characterize the audience. An advertiser chooses tags to characterize an advertising campaign or offer and the system determines which of the influences provide matches or partial matches to the advertising campaigns or offers. Influencers pick which campaigns they wish to offer to their audience and install a Widget on their website or page(s) that is used to display ads and process click-throughs. Influencers are rewarded with payments or reward incentives for placing the campaigns or offers and/or if the campaigns are successful. A web system is configured to provide the necessary functions to support the ad placement and rewards process. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a CDMA communication system, and more particularly to an apparatus and a method for securing a communication information in a CDMA communication system, thereby enabling the system to communicate privately with no overhearing.
2. Description of the Related Art
In a conventional CDMA communication system according to the IS-95 standard, a voice is encoded as an information bit by a vocoder (a voice encoder/decoder) and modulated in a reverse traffic channel. The modulated signal is transmitted to a base station. The modulated signal from the base station is reproduced as the original information bit in a forward traffic channel and it is decoded as an original voice by a vocoder. By the above process, it is possible to communicate between the remote mobiles.
However, the conventional CDMA system has the disadvantage that the information bit passing through only the vocoder can be detected at the base station or at a switching system, and the detected information bit can be easily decoded as the original voice. Thus, the conventional CDMA system has weakness for an overhearing.
U.S. Pat. No. 5,727,064 discloses the technique for solving the disadvantage, wherein a scrambler is added to a longcode generator. But, the technique can not be applied to the conventional CDMA system without any change because it requires the modification of IS-95 CDMA facilities, and it has a limit to communicate between the different user groups using the different security keys.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an apparatus and a method for securing a communication information in a CDMA communication system, which enables the system to communicate privately with no overhearing while the modification of the conventional base station and the switching system according to IS-95 standard is not required.
The foregoing object is accomplished in the present invention by an apparatus for securing communication information in CDMA communication system comprising a vocoder encoding the input analog signal as an information bit having a predetermined size and generating a vocoder packet information bit, and an encryptor encrypting the vocoder packet information bit from said vocoder, and a CDMA framer adding a frame quality indicator and the encoder tail bits to the encrypted vocoder packet information bit from said encryptor to configure as a CDMA frame, and a CDMA frame transmitter transmitting the CDMA frame which passes a convolutional encoder, interleaver, and modulator in sequence, to abase station through an assigned frequency band, and a CDMA frame receiver receiving a signal from the base station and reproducing the CDMA frame, and a CDMA deframer extracting the encrypted vocoder packet information bit from the CDMA frame reproduced by said CDMA frame receiver, and a decryptor decrypting the encrypted vocoder packet information bit extracted by said CDMA deframer, and a vocoder decoding the decrypted vocoder packet information bit from said decryptor as an analog signal, wherein said encryptor encrypts the vocoder packet information bit using a block cipher and a security key, said decryptor decrypts the encrypted vocoder packet information bit using said block cipher and a security key shared with the other mobile.
In addition, the foregoing object is accomplished in the present invention by providing a method for securing communication information in CDMA communication system comprising the steps of encoding a input analog signal as an information bit having a predetermined size and generating a vocoder packet information bit, and encrypting said encoded vocoder packet information bit using a block cipher and a security key, and adding a frame quality indicator and the encoder tail bits to the encrypted vocoder packet information bit and configuring it as a CDMA frame, and transmitting the CDMA frame which passes a convolutional encoder, interleaver, and modulator in sequence, to a base station through an assigned frequency band.
The foregoing object is also accomplished in the present invention by providing a method for securing communication information in CDMA communication system comprising the steps of receiving a signal from a base station, and reproducing it as a CDMA frame, extracting an encrypted vocoder packet information bit from the reproduced CDMA frame, and decrypting the encrypted vocoder packet information bit by a block cipher and a security key, and decoding the decrypted vocoder packet information bit.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will be more clearly understood from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram showing the traffic channel according to the present invention;
FIG. 2 shows a DES algorithm applicable to the present invention;
FIG. 3 shows an illustrated single iteration in the DES algorithm of FIG. 2 ;
FIG. 4 shows a flow diagram of encryption/transmission process according to a preferred embodiment of the present invention;
FIG. 5 is a flow diagram showing reception/decryption process according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. Reverse/Forward Traffic Channel
FIG. 1 is a block diagram showing the traffic channel according to the present. In FIG. 1 , a dotted block shows an essential part of the invention.
Referring to FIG. 1 , a reverse traffic channel will be described in the following.
A voice from a microphone is encoded as a vocoder packet information bit 141 by a vocoder 100 , and transmitted to an encryptor 140 . Using a block cipher 170 such as DES and triple DES, the encryptor 140 encrypts all or the part of the vocoder packet information bits 141 from the vocoder 100 and generates an encrypted vocoder packet information bit 142 and sends it to a CDMA framer 110 . In the encryption process, a security key 160 is used, which is stored in the encryptor 140 or exchanged in a safe manner.
A CDMA framer 110 performs the process for making a CDMA frame by adding a frame quality indicator and the encoder tail bits to the encrypted vocoder packet information bit 142 .
Now, Referring to FIG. 1 , a forward traffic channel will be described.
Using a block cipher 170 identical to that in the reverse channel, a decryptor 150 decrypts all or the part of the encrypted vocoder packet information bits 152 from a CDMA deframer 120 to reproduce the original vocoder packet information bit 151 and sends them to a vocoder 130 . In the decryption process, a security key 160 is also used, which is stored in the decryptor 150 or exchanged in a safe manner. Here, the CDMA deframer 120 performs the reverse process as that of the CDMA framer 110 .
2. Encryption/Decryption
The encryption of the vocoder packet information bit 141 and the decryption of the encrypted vocoder packet information bit 152 are performed in bite by the block cipher 170 , and thus only the information bits corresponding to a multiple of 8 are encrypted or decrypted.
For Example, in IS-95A 9600bps frame, only 21 bytes are encrypted/decrypted since the number of the information bits are 172 bits (=8×21+4). At the information bits of 172 bits ( 1 ) if it's a full rate, all 171 bits (vocoder output) excepting the first 1 bit Format bit ( 0 ) are encrypted/decrypted, and ( 2 ) if it isn't a full rate (for example, ½ rate, 80 bits), the bits, which corresponds to output of the vocoder, of the remaining 168 bits excepting the first 4 bits Format bits (for example ½ rate 1000), that is, only a part of the ½ bits are encrypted/decrypted. However, when the amount of the calculations are too much to be encrypted/decrypted in a given time, only the part of them (for example, 8 bytes) are encrypted/decrypted. In addition, when the output of the vocoder 100 is a mute (⅛ rate), (which is different in size according to vocoder, and is usually discriminated throuah format bits) the encryption/decryption process may be omitted in order to prevent a repeated transmission of the same pattern or in or to prevent a noise. Using a software or a hardware, the encryptor 140 and decryptor 150 performs the encryption/decryption process every 20 ms after the vocoder completes the encoding.
For the encryption/decryption, assume the case using the DES (Data Encryption Standard) selected as a FIPS PUB 46 (Federal Information Processing Standard 46) by the NIST (National Institute of Standards and Technology).
FIG. 2 shows a DES algorithm applicable to the present invention and FIG. 3 shows an illustrated single iteration in the DES algorithm of FIG. 2 using a 64 bits text and 56 bits security key. In this case, for example, assume that only the first 8 bytes of the 172 bits are encrypted/decrypted in a full rate. Then, the 64 bits plain text (for example, 01 23 45 67 89 ab cd e7) of FIG. 2 expresses the first 8 bytes which corresponds to pure output of the vocoder of the 172 vocoder packet information bits transmitted from the vocoder 100 , and 56 bits key (for example, 01, 23, 45, 67 89 ab de) of FIG. 2 indicates a security key 160 which a sending and a receiving mobile are sharing. The 172 encrypted vocoder packet information bits are obtained by adding the remaining unencrypted 108 bits to the 64 bits cipher text (for example, c9 57 44 25 6a 5e d3 1d) from the encryptor 140 in front and back of the formal bits and the remaining vocoder output.
A decryption process, which is a reverse process of the encryption, will be described. The original 64 bits plain text (for example, 01 23 45 67 89 ab cd; FIG. 4 ) is obtained by decrypting the 8 encrypted bytes (i.e. 64 bits cipher text in FIG. 2 (for example, c9 57 44 25 6a 5e d3 1d)) among the 172 encrypted vocoder packet information bits from the CDMA deframer 120 and 56 bits key in FIG. 2 (for example, 01 23 45 67 89 ab cd), in a reverse order as in the encryption process. The 172 vocoder packet information bits generated by adding a remaining 108 bits to the 64 bits plain text are transmitted to the vocoder 130 and decoded therein to reproduce the original voice.
The block cipher such as DES and triple DES is used for the encryption/decryption process.
3. Security Mode On/OFF
For a communication with the mobiles to which the above security method can not be applied, a sending mobile is set to the security mode On or Off if a predefined key is entered at the beginning of the communication, and a receiving mobile is also set to the security mode On or Off identically to the sending mobile. This enables the remote mobiles to communicate privately without any overhearing. Such security mode ON/OFF with the predefined key may be performed before a call setup, or may be performed during the communication after a call setup.
The security mode ON is performed as the following. An ON key requesting the security mode is entered in a reverse traffic channel. Then, a first pattern (distinguished from the vocoded voice) corresponding to the security mode ON is transmitted to the other mobile with the information bit. The other mobile receives and checks the first pattern to set the security mode ON.
The security mode OFF is performed as the following. An OFF key is entered during the communication and a second pattern (distinguished from the vocoded voice) corresponding to the security mode OFF is transmitted to the other mobile with the information bit. The other mobile receives and checks the second pattern to set the security mode OFF and returns back to the normal mode. Alternatively, the security mode may be automatically set to OFF when the communication is completed. With this method, it is possible to repeat the security mode ON/OFF during the communication.
In a weak wave area, an error may be occurred in the patterns transmitted for the security mode ON/OFF and thus it may be happened that the receiving mobile can not be set to the security mode ON/OFF. Then, it is impossible to communicate between the remote mobiles because the sending mobile is set to the security mode On and the receiving mobile to the security mode OFF. This can be settled with the following solutions; 1) sending the security mode ON/OFF signal repeatedly to reduce the occurrence of the error, or 2) informing the receipt of the security mode On/OFF signal by sending a ECHO signal from the receiving mobile to the sending mobile when the sending mobile transmits the security mode On/OFF signal to the receiving mobile and communicating each other after the sending mobile detects the ECHO signal from the receiving mobile and sets the security mode to ON/OFF.
The ON key and the OFF key used to set the security mode ON/OFF are selected among the keys which does not affect the communication. Further, in the case that the security mode is set to ON, the security key in the block cipher may be transmitted with the ON key or a scheme for finding out the security key may be transmitted with the ON key, which will be described in the following.
4. Mute Handling
Generally, a mute denotes a condition that no voice is detected for 20 ms. In the case of the mute, the encryption process in the encryptor 140 and the decryption process in the decryptor 150 may be bypassed by the signals MUTE — Tx 143 or MUTE — Rx 153 , and further may be bypassed by a signal Security — Mode 180 in accordance with the security mode.
TABLE 1
Operation of the encryptor in accordance with
the security mode and the mute
Security Mode
Security — Mode
Security — Mode
MUTE — Rx
ON
OFF
MUTE — Tx ON
bypass
bypass
MUTE — Tx OFF
encryption
bypass
TABLE 2
Operation of the decryptor in accordance with
the security mode and the mute
Security Mode
Security — Mode
Security — Mode
MUTE — Rx
ON
OFF
MUTE — Rx ON
bypass
bypass
MUTE — Rx OFF
decryption
bypass
Tables 1 and 2 shows the operation of the encryptor and the decryptor in accordance with the security mode and the mute, respectively. Referring Tables 1 and 2, the encryption and the decryption are all bypassed when the signal Security — Mode 180 is OFF. In addition, altough the signal Security — Mode 180 is ON, the encryption and the decryption are also bypassed when the signals MUTE — Tx 143 or MUTE — Rx 153 is ON.
The signals MUTE — Tx 143 and the MUTE — Rx 153 , which indicate whether the present vocoder packet contains the information corresponding to the mute, can be expressed by a flag in a software implementation and can be handled as an additional signal in a hardware implementation. The signal Security — Mode 180 indicates whether the security mode is ON or OFF.
In a fixed rate, a separate process is not required when the mute happens. However, in a variable rate when the mute happens, it is possible to easily cheek the mute status of the frame through format its of the vocoder packet without any special process. In this case, the encryption and decryption is not performed. Accordingly, a new logic is not needed for the implementation of the present invention.
5. Sharing Security Key
The block ciphers for the encryptor 140 and the decryptor 150 use the same algorithm and the same security key. For this reason, there is required a scheme for sharing the security key between a transmitter and a receiver remotely separated from each other.
A first scheme is to send a security key from the transmitter to the receiver when the security mode is set to ON. For example, when the security mode is set to ON, the 172 information bits in a IS-95 9600 bps frame are transmitted as a specific pattern (for example, 5555 . . . 555 in Hexadecimal) denoting a Security — Mode ON, and then the 128 bits in a next frame (if the security key is 128 bits) is defined as a security key, or a security key encrypted by a master key (generally called as a session key and used as a disposable key) is transmitted. When the master key is used, the mobiles in communication share the same master key, which is stored at an authorized organization.
A second scheme is to specify one of the keys stored in a transmitter and a receiver in the same manner (for example, 100 keys of 128 bits) when the security mode is set to ON. In other words, among the 172 information bits in a IS-95 9600 bps frame, for example 164 bits are transmitted as a specific pattern (such as 5555 . . . 5 in hexadecimal) denoting the security mode ON and the remaining 8 bits are used as an index of the 256 security keys stored in secrecy. At this time, the stored security keys may be configured as the security keys which the mobile manufacturer provides and the security keys which a subscriber enters by himself.
A third scheme is that the two subscribers exchange only the security key via a separate call. The key to be exchanged can be obtained by the subscribers' entrance or by a random number generator in the mobile. The security key exchanged according to the third scheme is specified and used by the second scheme when the security mode is set to ON.
6. Encryption/Transmission Process
FIG. 4 shows a flow diagram of the encryption/transmission process according to a preferred embodiment of the present invention. Referring FIG. 4 , an encryption process will be described in detail.
First, when the power of the transmitter is ON, the initialized process in the transmitter is performed (step 400 ). Consequently, when a subscriber enters a key to request a call (step 405 ) , the call is setup (step 410 ). At this time, if the entered key is the security mode ON key (step 415 and 420 ), then the security mode of the transmitter is set to ON (step 425 ) and the specific pattern indicating the Security — Mode ON and an index of the security key selected among the multiple security keys in the transmitter are added to the information bit in the traffic channel (step 430 ).
If the entered key is the security mode OFF key (step 415 and 420 ), then the security mode of the transmitter is set to OFF (step 435 ) and the specific pattern indicating the Security — Mode OFF is added to the information bit in the traffic channel (step 440 ).
If the security mode key is not entered in the step 415 , then an input signal is encoded as an information bit and the vocoder packet information bit is generated by a vocoder (step 445 ). If the security mode is on (step 450 ) and the vocoder packet information bit is not a mute (step 445 ), then the vocoder packet information bit is encrypted using a block cipher and a security key (step 460 ). Otherwise, the steps 455 and 460 are bypassed. In a CDMA framer, the frame quality indicator and the encoder tail bits are added to such encrypted or unencrypted vocoder packet information bit to configure a CDMA frame (step 465 ), and then the CDMA frame passes a convolutional encoder, interleaver, and modulator in sequence, and finally transmitted to a base station through an assigned frequency band (step 470 ). In a step 475 , if the call is maintained, then the routine is returned to the step 415 . If the call is completed, then the security mode is set to a normal mode (step 480 ) and the routine is returned to the step 405 .
Each functions in relation to the encryption process of the invention may be implemented by a software or a hardware such as ASIC (Application Specific Integrated Circuit)
7. Reception/Decryption Process
FIG. 5 shows the flow diagram of the reception/decryption process according to a preferred embodiment of the present invention, at the receiver corresponding to the transmitter in FIG. 4 . Referring FIG. 5 , the reception/decryption process will be described in detail.
First, when the power of the receiver is ON, the initialized process in the receiver is performed (step 500 ). Consequently, when a ring and a call are received (step 505 ), the call is setup between the transmitter and the receiver (step 510 ). Then, the receiver receives a modulated signal from the base station and reproduces the CDMA frame from the signal (step 515 ). The CDMA deframer extracts an encrypted vocoder packet information bit from the reproduced CDMA frame (step 520 ). The decryptor determines if a security mode pattern is included in the encrypted vocoder packet information bit (step 525 ). If the security mode pattern indicates the Security — Mode ON (step 530 ), then the decryptor checks an index included in the information bit and determines a security key corresponding to the index among the multiple security keys in the receiver (step 535 ), and the security mode of the receiver is set to ON (step 540 ). In the step 530 , if the security mode pattern in the information bit indicates the Security — Mode OFF, then the security mode of the receiver is set to OFF (step 545 ).
In the case that the security mode pattern is not included in the vocoder packet information bit in a step 525 , if the security mode of the receiver is ON (step 550 ) and the encrypted vocoder packet information bit is not a mute (step 555 ), then the decryptor decrypts the encrypted vocoder packet information bit using a block cipher and the security key (step 560 ). Otherwise, the steps 555 and 560 are bypassed. Such decrypted or bypassed vocoder packet information bit is decoded by the vocoder (step 565 ).
If the call is maintained in a step 570 , then the routine is returned to the step 515 . If the call is completed in the step 570 , then the security mode is set to a normal mode (step 575 ) and the routine is returned to the step 505 .
Each function in relation to the decryption process of the invention may be also implemented by a software or a hardware such as ASIC (Application Specific Integrated Circuit).
As described above, the present invention performs the encryption process between the vocoder and CDMA framer in the reverse traffic channel through the block cipher and performs the decryption process between the vocoder and CDMA deframer in the forward traffic channel through the block cipher.
Accordingly, since the information bit is transmitted in an encrypted form except for the receiver and transmitter, it is impossible to decrypt the encrypted information bit as the original vocoder packet without exactly knowing the algorithm and the security key, even if the encoded information bit is detected by an advanced technique.
Further, the invention has the advantage that, without the modification of the conventional base station and the switching system according to IS-95 standard, it enables the CDMA system to communicate privately with no overhearing.
The invention also provides the simple and safe method for sharing the security key, to thereby allow the communication between the different user groups using the different security key. Thus, it is possible to build up the security network readily among the small user groups.
The present invention has been described in terms of preferred embodiments. However, it should be understood that the present invention is not limited in its application to the specific embodiments. Those skilled in the art will recognize that various modifications and variations may be made without departing from the spirit and scope of this invention, as defined in the following claims. | An apparatus and a method for securing a communication information in a CDMA communication system are disclosed. The method of the invention comprises the steps of encoding a input analog signal as an information bit having a predetermined size and generating a vocoder packet information bit, and encrypting said encoded vocoder packet information bit using a block cipher and a security key, and adding a frame quality indicator and the encoder tail bits to the encrypted vocoder packet information bit and configuring it as a CDMA frame, and transmitting the CDMA frame which passes a convolutional encoder, interleaver, and modulator in sequence, to a base station through an assigned frequency band.
Further, The method of the invention comprises the steps of receiving a signal from a base station, and reproducing it as a CDMA frame, and extracting an encrypted vocoder packet information bit from the reproduced CDMA frame, and decrypting the encrypted vocoder packet information bit by a block cipher and a security key, and decoding the decrypted vocoder packet information bit. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates a cooling technology for electronic products, and, more particularly, to a complex signal processing system and related method for controlling multiple fans.
2. Description of the Related Art
With the rapid pace of improvements in semiconductor technologies, the number of transistors in a single integrated circuit (IC) has increased dramatically, and the execution speeds of integrated circuits have also seen dramatic increases. As a result, it has become very important to improve the cooling capabilities for these integrated circuits.
FIG. 1 is a schematic drawing of a fan control module in the prior art. The hardware monitor 110 uses TACH pins 1 ˜ 4 to receive and process fan speed signals (tachometer signals). The hardware monitor 110 has specific fan control pins for sending pulse width modulation (PWM) signals to control the speed of the fans. However, the number of pins available for the hardware monitor 110 is limited, and when there are more fans, more hardware monitors are required. When the pins for the hardware monitor 110 are insufficient, even the addition of a single fan requires the addition of another hardware monitor. As shown in FIG. 1 , hardware monitors 110 , 120 each have four pairs of fan control pins; the fans 131 , 132 , 133 , 134 are controlled by the hardware monitor 110 , and a single fan 135 is controlled by the hardware monitor 120 . Therefore, under this configuration, the additional hardware monitor 120 occupies space on the motherboard with extra fan control pins unused.
It is therefore desirable to provide a complex signal processing system and related method for controlling multiple fans to mitigate and/or obviate the aforementioned problems.
SUMMARY OF THE INVENTION
A main objective of the present invention is to provide a complex signal processing system and related method for controlling multiple fans, which can avoid too many hardware control circuit to save space and cost. According to an aspect of the present invention, a complex signal processing system for controlling a plurality of fans comprises: at least a first fan and a second fan, at least a logic gate, a hardware monitor and a control device. The first fan and the second fan separately have an output pin for outputting a speed signal indicating the rotational speed of the first fan or the second fan. The logic gate is connected to the respective output pins of the first fan and the second fan, for executing a logical operation upon the speed signal of the first fan and the speed signal of the second fan to generate a complex speed signal. The hardware monitor is connected to the logic gate, for receiving the complex speed signal and converting the complex speed signal into complex digital speed data. The control device is coupled to the hardware monitor for receiving the complex digital speed data and calculating a rotational speed of the first fan and the second fan according to the complex digital speed data.
According to another aspect of the present invention, complex signal processing method for a plurality of fans including at least a first fan and a second fan, the method comprises: step A: separately driving the first fan and the second fan by at least one control signal to control their rotational speed; step B: executing a logical operation to a speed signal of the first fan and a speed signal of the second fan to generate a complex speed signal; and step C: converting the complex speed signal into complex digital speed data.
According to an embodiment of the present invention, the method further comprises: step D: calculating the rotational speed of the first fan and the second fan utilizing the complex digital speed data; the rotational speed of the first fan and the second fan is obtained by dividing the complex digital speed data by a total number of the first fan and the second fan; and step E: determining whether the first fan and the second fan is operating normally according to the calculated rotational speed.
According to the embodiment of the present invention, the method further comprises: step F: determining whether the first fan and the second fan is operating normally according to the complex digital speed data.
According to the embodiment of the present invention, determining whether the first fan and the second fan are operating normally in step E, F comprises determining whether the rotational speed of the first fan and the second fan is less than a predetermined speed and determining whether the times the rotational speed of the first fan and the second fan is less than a predetermined speed exceed the predetermined value. If the first fan and the second fan operate abnormally, a step of generating a warning signal is performed to warn users, e.g. via an LED, a speaker, or a buzzer, etc.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of a prior art fan control module.
FIG. 2 is a functional block drawing of a complex signal processing system for controlling multiple fans according to the present invention.
FIG. 3 is a flow chart of a complex signal processing method for controlling multiple fans according to the present invention.
FIG. 4A is a timing diagram that shows the wave phases of two fan speed signals being identical when a logic gate executes an XOR logical operation.
FIG. 4B is a time sequence diagram that shows the wave phases of two fan speed signals being different when a logic gate executes an XOR logical operation.
FIG. 5 is a schematic drawing of another embodiment according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 is a functional block drawing of a complex signal processing system for controlling multiple fans according to the present invention. The system comprises a first fan 210 , a second fan 220 , a logic gate 230 , a hardware monitor 240 , a control device 250 and a warning device 260 .
The first fan 210 and the second fan 220 respectively have control pins 211 , 221 and output pins 212 , 222 . The control pins 211 , 221 receive a control signal PWM 4 to drive and control the rotational speed of the first fan 210 and the second fan 220 ; the output pins 212 , 222 output a speed signal indicating the rotational speed of the first fan 210 and the second fan 220 . The first fan 210 and the second fan 220 preferably have rated speed characteristics, meaning that these two fans should have the same maximum average rotational speed under the same controlled environmental conditions.
A first input end 231 of the logic gate 230 is connected to the output pin 212 of the first fan 210 , and a second input end 232 of the logic gate 230 is connected to the output pin 222 of the second fan 220 , to execute a logical operation on the speed signal of the first fan 210 and the speed signal of the second fan 220 , thereby generating a complex speed signal. The logic gate 230 is preferably an XOR gate, which can execute an XOR logical operation upon the speed signal of the first fan 210 and the speed signal of the second fan 220 to generate the complex speed signal.
The hardware monitor 240 is connected to the logic gate 230 and used for receiving the complex speed signal and converting the complex speed signal into complex digital speed data. For example, the hardware monitor 240 converts the pulse of the complex speed signal into a 16-bit digital value and stores it in a 16-bit register for being read by the control device 250 . The hardware monitor 240 further comprises a PWM control circuit 241 and a tachometer 242 .
The control circuit 241 is connected to the control pins 211 , 221 of the first fan 210 and the second fan 220 to output a control signal PWM 4 to the control pins 211 , 221 of the first fan 210 and the second fan 220 , thus controlling the speeds of the first fan 210 and the second fan 220 . The control signal PWM 4 is a pulse-width modulation (PWM) signal. Actually, the control signals PWM 1 , PWM 2 , PWM 3 , PWM 4 may all be used for controlling the first fan 210 and the second fan 220 , and under the same speed settings, the first fan 210 and the second fan 220 can be controlled by different control signals.
The tachometer 242 is connected to an output pin 233 of the XOR gate 230 , receiving the complex speed signal and trigging the tachometer 242 to perform signal conversion based on the edge of the complex speed signal. The tachometer 242 converts the number of pulses of the received complex speed signal in a unit of time into complex digital speed data, and stores the complex digital speed data in the register.
The control device 250 is coupled to the hardware monitor 240 to receive the complex digital speed data and calculate the speed of the first fan 210 and the second fan 220 based upon the complex digital speed data. The control device 250 divides the complex digital speed data by two and uses this half-value as the speed of the first fan 210 and the second fan 220 . The control device 250 reads the register for the tachometer 242 regularly to obtain new complex digital speed data.
The warning device 260 is connected to the control device 250 , and when the speed of the first fan and the second fan falls below a predetermined value, the control device 250 generates a warning signal and drives warning device 260 with the warning signal. The warning device 260 may be an LED, which generates a visual warning signal according to the warning signal. The warning device 260 can also be a speaker or a buzzer, which then generates an audio warning signal according to the warning signal.
To avoid noise interfering with the complex digital speed data received by the control device 250 , the control device 250 determines whether the times the speed of the first fan and the second fan has fallen below the predetermined speed exceed a predetermined value (e.g., more than 10 times) before generating the warning signal. When the control device 250 determines that the times, in which the speed of the first fan 210 and the second fan 220 has fallen below the predetermined speed, has exceeded the predetermined value, a state indicating that the speed of the first fan 210 and the second fan 220 has fallen below the predetermined speed for a while, the control device 250 generates the warning signal.
Please refer to FIG. 3 . FIG. 3 is a flow chart of a complex signal processing method for controlling multiple fans according to the present invention. The flow chart shows how to process the speed signal of the first fan 210 and the second fan 220 . First, in step S 310 , the hardware monitor 240 uses at least one PWM control signal to drive the first fan 210 and the second fan 220 and to control their speed.
In step S 320 , the logic gate 230 is utilized to execute an XOR logical operation upon the speed signals of the first fan 210 and the second fan 220 to generate a complex speed signal.
Please refer to FIG. 4A and FIG. 4B . FIG. 4A is a timing diagram showing the wave phases of two fan speed signals being identical when the logic gate executes an XOR logical operation. FIG. 4B is a timing diagram showing the wave phases of two fan speed signals being different when the logic gate executes an XOR logical operation. The first fan 210 and the second fan 220 may have the same rated speed, and both may use the same PWM signal PWM 4 for speed control. However, due to variables such as internal friction, mechanical variations, etc., the speed signal of the first fan 210 and the second fan 220 may have a phase offset instead of being identical to the wave phase shown FIG. 4A . The edges A˜G shown in FIG. 4B can trigger the tachometer 242 to perform the signal conversion. In step S 330 , the hardware monitor 240 converts the complex speed signal into the complex digital speed data.
In step S 340 , the control device 250 calculates the speed of the first fan 210 and the second fan 220 using the complex digital speed data. The control device 250 divides the complex digital speed data into half and uses the halved value as the speed of the first fan 210 and the second fan 220 . Please refer to the wave form for the pin 233 , shown in FIG. 4B . For the XOR logical operation performed by the logic gate 230 , the number of positive edges of the wave form of the pin 233 is substantially equal to the total number of positive edges of the wave forms for the pin 231 and the pin 232 . Therefore, a halved value of the complex digital speed data may be viewed as the speed of the first fan 210 and the second fan 220 . In the other words, by dividing the complex digital speed data by the total number of fans, the speed for each fan may be obtained.
In step S 350 , the control device 250 determines whether the speed of the first fan 210 and the second fan 220 has fallen below the predetermined speed. When the control device 250 determines that the speed of the first fan 210 and the second fan 220 is less than the predetermined speed, the control device 250 determines whether the times the speed of the first fan 210 and the second fan 220 has been less than the predetermined speed exceed the predetermined value (step S 360 ).
In step S 370 , when the control device 250 determines the times the speed of the first fan 210 and the second fan 220 being lower than the predetermined speed has exceeded a predetermined value, the control device 250 generates a warning signal and drives the warning device with the warning signal. The warning signal can be a visual warning signal or an audio warning signal.
In step S 350 , when the control device 250 determines that the speed of the first fan and the second fan is not less than the predetermined value, step S 320 is executed. In step S 360 , when the control device 250 determines that the times the speed of the first fan 210 and the second fan 220 is less than the predetermined speed do not exceed the predetermined value, step S 320 is executed.
In step S 340 , it may not be necessary to divide the complex digital speed data into half to obtain the speed of the first fan 210 and the second fan 220 . For example, if the complex digital speed data is 300 rev/sec, step S 340 may calculate the speed of the first fan 210 and the second fan 220 to be about 150 rev/sec, and step S 350 may determine whether 150 rev/sec is less than the predetermined speed (assuming, for example, that the predetermined speed is 200 rev/sec). If step S 340 is skipped, step S 350 can be changed to determine whether the complex digital speed data (300 rev/sec) exceeds more than twice of the predetermined speed (e.g., 400 rev/sec=2×200 rev/sec).
When the present invention is utilized for more than two fans, the speed of each fan can be obtained by dividing the complex digital speed data by the number of fans. However, when there are more than two fans, more logic gates are required, and all of speed signals should be processed by several XOR logical operations. For example, four speed signals from four fans may use three XOR gates to perform three XOR logical operations to provide the complex speed signal.
Please refer to FIG. 5 . FIG. 5 is a schematic drawing of another embodiment according to the present invention. In FIG. 5 , fans 131 , 132 , 133 , 210 , 220 and logic gate 230 are all installed in a fan module 600 , such as a fan switch board. The hardware monitor 240 and the warning device 260 are installed on a motherboard 500 . The control device 250 is replaced by a processor 550 , a south bridge 552 , a memory 560 and a super I/O controller 554 . The south bridge 552 reads the complex digital speed data from the hardware monitor 240 via a SM Bus; the memory 560 stores basic input output system (BIOS) program code and control programs for the fans 131 , 132 , 133 , 210 , 220 , which are executed by the processor 550 ; the super I/O controller 554 is connected to the south bridge 552 and the LED 262 . When the fans malfunction, the super I/O controller 554 controls the LED 262 accordingly. Under certain conditions, the south bridge 552 can directly control the LED 262 . The fan module 600 may be connected to a connector 580 on the motherboard 500 via a connector 570 , and the connectors 570 , 580 can be pin headers.
In certain embodiments, the control device may be provided by an integrated circuit.
Accordingly, the present invention uses the control signal PWM 4 output by the hardware monitor 240 to control the speed of the first fan 210 and the second fan 220 . The logic gate 230 may used to provide an XOR logical operation to the speed signal of the first fan 210 and the second fan 220 , thus reducing the pin requirements of the hardware monitor 240 , which can save space and manufacturing costs.
Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. | A complex signal processing system for multiple fans is used to control the rotation of a first fan and a second fan. The speed signals of the first fan and the second fan are processed through an XOR operation to obtain a complex speed signal. In response to the complex speed signal, the speed and the operational status of the first fan and the second fan can be evaluated. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/502,164, filed Jul. 13, 2009, which is a continuation of U.S. patent application Ser. No. 11/112,847, filed Apr. 22, 2005, now U.S. Pat. No. 7,641,686, which claims priority under 35 U.S.C. §119(e) to (1) U.S. Provisional Patent Application No. 60/564,708, filed Apr. 23, 2004, (2) U.S. Provisional Patent Application No. 60/568,402, filed May 5, 2004, (3) U.S. Provisional Patent Application No. 60/572,561, filed May 19, 2004, (4) U.S. Provisional Patent Application No. 60/581,664, filed Jun. 21, 2004, (5) U.S. Provisional Patent Application No. 60/586,054, filed Jul. 7, 2004, (6) U.S. Provisional Patent Application No. 60/586,110, filed Jul. 7, 2004, (7) U.S. Provisional Patent Application No. 60/586,005, filed Jul. 7, 2004, (8) U.S. Provisional Patent Application No. 60/586,002, filed Jul. 7, 2004, (9) U.S. Provisional Patent Application No. 60/586,055, filed Jul. 7, 2004, (10) U.S. Provisional Patent Application No. 60/586,006, filed Jul. 7, 2004, (11) U.S. Provisional Patent Application No. 60/588,106, filed Jul. 15, 2004, U.S. Provisional Patent Application No. 60/603,324, filed Aug. 20, 2004, (12) U.S. Provisional Patent Application No. 60/605,204, filed Aug. 27, 2004 and (13) U.S. Provisional Patent Application No. 60/610,269 filed Sep. 16, 2004, the entire contents of which are hereby expressly incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] According to recent estimates, more than 79,000 patients are diagnosed with aortic and mitral valve disease in U.S. hospitals each year. More than 49,000 mitral valve or aortic valve replacement procedures are performed annually in the U.S., along with a significant number of heart valve repair procedures.
[0003] Although mitral valve repair and replacement can successfully treat many patients with mitral valvular insufficiency, techniques currently in use are attended by significant morbidity and mortality. Most valve repair and replacement procedures require a thoracotomy, usually in the form of a median sternotomy, to gain access into the patient's thoracic cavity. A saw or other cutting instrument is used to cut the sternum longitudinally, allowing the two opposing halves of the anterior or ventral portion of the rib cage to be spread apart. A large opening into the thoracic cavity is thus created, through which the surgical team may directly visualize and operate upon the heart and other thoracic contents. Alternatively, a thoracotomy may be performed on a lateral side of the chest, wherein a large incision is made generally parallel to the ribs, and the ribs are spread apart and/or removed in the region of the incision to create a large enough opening to facilitate the surgery.
[0004] Surgical intervention within the heart generally requires isolation of the heart and coronary blood vessels from the remainder of the arterial system, and arrest of cardiac function. Usually, the heart is isolated from the arterial system by introducing an external aortic cross-clamp through a sternotomy and applying it to the aorta to occlude the aortic lumen between the brachiocephalic artery and the coronary ostia. Cardioplegic fluid is then injected into the coronary arteries, either directly into the coronary ostia or through a puncture in the ascending aorta, to arrest cardiac function. The patient is placed on extracorporeal cardiopulmonary bypass to maintain peripheral circulation of oxygenated blood.
[0005] A need therefore remains for methods and devices for treating mitral valvular insufficiency, which are attended by significantly lower morbidity and mortality rates than are the current techniques, and therefore would be well suited to treat patients with dilated cardiomyopathy. Optimally, the procedure can be accomplished through a percutaneous, transluminal approach, using simple, implantable devices.
[0006] The circulatory system is a closed loop bed of arterial and venous vessels supplying oxygen and nutrients to the body extremities through capillary beds. The driver of the system is the heart providing correct pressures to the circulatory system and regulating flow volumes as the body demands. Deoxygenated blood enters heart first through the right atrium and is allowed to the right ventrical through the tricuspid valve. Once in the right ventrical, the heart delivers this blood through the pulmonary valve and to the lungs for a gaseous exchange of oxygen. The circulatory pressures carry this blood back to the heart via the pulmonary veins and into the left atrium. Filling of the left ventricle occurs as the mitral valve opens allowing blood to be drawn into the left ventrical for expulsion through the aortic valve and on to the body extremities. When the heart fails to continuously produce normal flow and pressures, a disease commonly referred to as heart failure occurs.
[0007] Heart failure simply defined is the inability for the heart to produce output sufficient to demand. Mechanical complications of heart failure include free-wall rupture, septal-rupture, papillary wall rupture or dysfunction aortic insufficiency and tamponade. Mitral, aortic or pulmonary valve disorders lead to a host of other conditions and complications exacerbating heart failure further. Other disorders include coronary disease, hypertension, and a diverse group of muscle diseases referred to as cardiomyopothies. Because of this syndrome establishes a number of cycles, heart failure begets more heart failure.
[0008] Heart failure as defined by the New York Heart Association in a functional classification.
[0009] Patients with cardiac disease but without resulting limitations of physical activity. Ordinary physical activity does not cause undue fatigue, palpitation, dyspnea, or anginal pain.
[0010] Patient with cardiac disease resulting in slight limitation of physical activity. These patients are comfortable at rest. Ordinary physical activity results in fatigue, palpitation, dyspnea, or anginal pain.
[0011] Patients with cardiac disease resulting in marked limitation of physical activity. These patients are comfortable at rest. Less than ordinary physical activity causes fatigue palpitation, dyspnea, or anginal pain.
[0012] Patients with cardiac disease resulting in inability to carry on any physical activity without discomfort. Symptoms of cardiac insufficiency or of the anginal syndrome may be present even at rest. If any physical activity is undertaken, discomfort is increased.
[0013] Congestive heart failure is described as circulatory congestion including peripheral edema. The major factor in cardiac pulmonary edema is the pulmonary capillary pressure. There are no native valves between the lungs and the left atrium therefore fluctuations in left atrial pressure are reflected retrograde into the pulmonary vasculature. These elevations in pressure do cause pulmonary congestion. When the heart, specifically the mitral valve, is operating normally correct flow and pressures throughout the circulatory system are maintained. As heart failure begins these pressures and flow rates decrease or increase depending upon the disease and vascular location.
[0014] Placement of valves between the lung and the left atrium will prevent retrograde flow and undesired pressure fluctuations to the pulmonary vasculature. Mechanical valves may be constructed of conventional materials such as stainless steel, nickel-titanium, cobalt-chromium or other metallic based alloys. Other materials used are biocompatible-based polymers and may include polycarbonate, silicone, pebax, polyethylene, polypropylene or floropolymers such as Teflon. Mechanical valves may be coated or encapsulated with polymers for drug coating applications or favorable biocompatibility results.
[0015] There are many styles of mechanical valves that utilize both polymer and metallic materials. These include single leaflet, double leaflet, ball and cage style, slit-type and emulated polymer tricuspid valves. Though many forms of valves exist, the function of the valve is to control flow through a conduit or chamber. Each style will be best suited to the application or location in the body it was designed for.
[0016] Bioprosthetic heart valves comprise valve leaflets formed of flexible biological material. Bioprosthetic valve or components from human donors are referred to as homografts and xenografts are from non-human animal donors. These valves as a group are known as tissue valves. This tissue may include donor valve leaflets or other biological materials such as bovine pericardium. The leaflets are sewn into place and to each other to create a new valve structure. This structure may be attached to a second structure such as a stent or cage for implantation to the body conduit.
Description of the Related Art
[0017] The concept of placing a percutaneous valve in the pulmonary veins was first disclosed by Block et all in U.S. Pat. No. 5,554,185. A specific windsock valve for this application was later described by Shaknovich in U.S. Pat. No. 6,572,652.
SUMMARY OF THE INVENTION
[0018] There is provided in accordance with one aspect of the present invention, a flow controlled device dimensioned for implantation in a human pulmonary vein. The device comprises an inflatable support structure in at least one movable occluder that controls the flow of blood into and out of the pulmonary veins. Implantation of the valve between the left atrium and the lung within the pulmonary vein reduces the likelihood and/or the severity of regurgitant flow increasing the pulmonary pressure which may lead to pulmonary edema and congestion.
[0019] In accordance with a further aspect of the present invention, a method of monitoring a patient comprises monitoring blood flow through the pulmonary veins during the implantation of the device of Claim 1 . In accordance with a further aspect of the present invention, there is provided a method of monitoring blood pressure comprising monitoring blood pressure through the pulmonary veins during the implantation of the pulmonary vein valve.
[0020] In accordance with a further aspect of the present invention, there is provided a method of treating a patient comprising rerouting blood flow from the pulmonary veins into a prosthetic chamber, and then back into a portion of the heart. The prosthetic chamber may include at least one valve, and may serve as a manifold for combining the flow of the pulmonary veins into a single return conduit, which may be placed into communication with the left ventrical.
[0021] Further features and advantages of the present invention will become apparent to those of skill in the heart in view of the detailed description of preferred embodiments which follows, when considered together with the attached drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a side elevational schematic view of an axially actuated deployment device in accordance with the present invention.
[0023] FIG. 2 is a side elevational schematic view of a rotationally actuated deployment device in accordance with the present invention.
[0024] FIG. 3 is a fragmentary cut-away view of a distal end of a deployment catheter having an implantable device therein.
[0025] FIG. 4 is a fragmentary view as in FIG. 3 , having a different embodiment illustrated therein.
[0026] FIG. 5 is a simplified top view of a section through the heart, illustrating a first valve at a first location in a first pulmonary vein, and a second valve at a second location in a second pulmonary vein.
[0027] FIG. 6 is a schematic representation of a stent supported valve in a pulmonary vein.
[0028] FIG. 7 is a simplified back view of the heart, illustrating the location of the left superior pulmonary vein, left inferior pulmonary vein, right superior pulmonary vein and right inferior pulmonary vein.
[0029] FIG. 8 is a simplified view of the lungs and left atrium, illustrating the orientation of the pulmonary veins with respect to the lungs.
[0030] FIG. 9A is a perspective schematic view of a Starr-Edwards ball and cage valve.
[0031] FIG. 9B is a perspective schematic view of a single leaflet valve.
[0032] FIG. 9C is a schematic perspective view of a bi-leaflet valve.
[0033] FIG. 9D is a schematic perspective view of a Reed style or duckbill valve.
[0034] FIG. 9E is a schematic perspective view of a poly-leaflet valve.
[0035] FIG. 9F is a schematic perspective view of a tri-leaflet valve having an inflatable support structure.
[0036] FIG. 9G is a schematic perspective view of a tri-leaflet valve having an alternative inflatable support structure.
[0037] FIG. 9H is an elevational cross-sectional view through the valve of FIG. 9G .
[0038] FIG. 10 is a schematic representation of the heart and pulmonary venous circulation following redirection of the pulmonary venous flow into the left ventrical.
[0039] FIG. 11 is a cross-sectional view of a ball valve that can be used to control inflation of the inflatable support structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] Implantation of valves into the body has been accomplished by a surgical procedure or via percutaneous method such as a catheterization or delivery mechanism utilizing the vasculature pathways. Surgical implantation of valves to replace or repair existing valves structures include the four major heart valves (tricuspid, pulmonary, mitral, aortic) and some venous valves in the lower extremities for the treatment of chronic venous insufficiency. Implantation includes the sewing of a new valve to the existing tissue structure for securement. Access to these sites generally include a thoracotomy or a sternotomy for the patient and include a great deal of recovery time. An open-heart procedure can include placing the patient on heart bypass to continue blood flow to vital organs such as the brain during the surgery. The bypass pump will continue to oxygenate and pump blood to the body's extremities while the heart is stopped and the valve is replaced. The valve may replace in whole or repair defects in the patient's current native valve. The device may be implanted in a conduit or other structure such as the heart proper or supporting tissue surrounding the heart. Vessels entering or departing the heart have an attachment or connection interface where the two components join in transition. This transition may provide a secure tissue zone to attach a valve body to. Attachments methods may include suturing, hooks or barbs, interference mechanical methods or an adhesion median between the implant and tissue. Access to the implantation site may require opening the wall of the heart to access the vessel or heart tissue for attachment. It is also possible to implant the device directly into the vessel by slitting in the longitudinal direction or cutting circumferentially the vessel and suturing the vessel closed after insertion. This would provide a less invasive method to implant the device surgically.
[0041] Other methods include a catheterization of the body to access the implantation site. Access may be achieved under fluoroscopy visualization and via catheterization of the internal jugular or femoral vein continuing through the vena cava to the right atrium and utilizing a transeptal puncture enter the left atrium. Once into the left atrium conventional and new catheterization tools will help gain access to the pulmonary veins. Engagement of each of the pulmonary veins may require a unique guiding catheter to direct device or catheter placement. Monitoring of hemodynamic changes will be crucial before, during and after placement of the device. Pressure and flow measurements may be recorded in the pulmonary veins and left atrium. Right atrial pressures may be monitored separately but are equally important. Separate catheters to measure these values may be required.
[0042] Valve delivery may be achieved by a pushable deployment of a self expanding or shaped memory material device, balloon expansion of a plastically deformable material, rotational actuation of a mechanical screw, pulling or pushing force to retract or expose the device to the deployment site. To aid in positioning the device, radiopaque markers may be placed on the catheter or device to indicate relative position to known landmarks. After deployment of the devices the hemodynamic monitoring will allow the interventional cardiologist to confirm the function of the valves. It is possible to place and remove each valve independently as valves may not be required in all pulmonary veins.
[0043] Entry to the body with a catheter may include the internal jugular or femoral vein. This will allow the user to enter the right atrium either superior or inferiorly and complete a transeptal puncture for access into the left atrium. Another approach would be to enter the femoral, brachial or radial artery where the user could access the aortic valve entering the left ventrical. Advancing the device through the left ventrical and past the mitral valve the left atrium can be entered. Utilizing normal cath-lab tools such as guidewires and guide catheters the delivery system or catheter can be advanced to the deployment site. Guidewires may measure 0.010-0.035 inches in diameter and 120-350 centimeters in length. Slippery coatings may aid in the navigation to the implantation site due to the vast number of turns and the tortuerosity of the vasculature. A guide catheter may be used to provide a coaxial support system to advance the delivery catheter through. This guiding catheter may be about 60-180 cm in length and have an outer diameter of 0.040-0.250 inches. It would have a proximal and distal end with a connection hub at the proximal end and may have a radiopaque soft tip at the distal end. It may have a single or multilumen with a wall thickness of 0.005-0.050 inches and may include stiffening members or braid materials made from stainless steel, nickel-titanium or a polymeric strand. The catheter material may include extruded tubing with multiple durometer zones for transitions in stiffness and support. The inner diameter may have a Teflon lining for enhanced coaxial catheter movement by reducing the friction coefficient between the two materials.
[0044] As illustrated in FIG. 1 , the delivery catheter 10 would be constructed by normal means in the industry utilizing extruded tubing, braiding for stiffening means and rotational torqueability. The delivery catheter 10 has a proximal end 12 and distal end 14 where the proximal end 12 may have a connection hub to mate other cath-lab tools to. The distal end 14 may have a radiopaque marker to locate under fluoroscopy. The outer diameter would measure about 0.030-0.200 inches and have a wall thickness from about 0.005-0.060 inches. The overall length would range from about 80-320 centimeters and have a connection hub or hubs at the proximal end 12 to allow wires, devices and fluid to pass. The connection hub would be compatible with normal cath-lab components and utilize a threaded end and a taper fit to maintain seal integrity. The inner diameter of the catheter 10 would allow for coaxial use to pass items such as guidewires, devices, contrast and other catheters. An inner lining material such as Teflon may be used to reduce friction and improve performance in tortuous curves. In addition a braided shaft of stainless steel or Nitinol imbedded into the catheter shaft 16 may improve the torqueability and aid in maintaining roundness of the catheter lumen.
[0045] Multidurometer materials would help soften the transition zones and add correct stiffness for pushability in the body. These zones may be achieved through an extrusion process know as bump tubing. Where the material inner and outer diameter change during the extrusion process. The entire catheter shaft can be produced in one piece. Another method for producing such a catheter shaft is to bond separate pieces of tubing together by melting the two components together and forming a single tube with multiple diameters and or stiffness. The application of heat can be applied by laser or heated air that flows over the shaft material or other methods of heat application sufficient to flow the materials together.
[0046] The shaft material may also consist of stiffening members for transition zones or bump extrusions to reduced diameter and maintain correct pushability. Lumen characteristics may include single or multi portals for guidewire or device entry. Conventional guidewire passage through the catheter such as “over-the-wire” may be used or technology such as “rapid-exchange” may aid in procedure ease and catheter exchanges. Since multiple devices may be placed in a single catheterization, rapid-exchange may be preferred but not essential. Other features that may aid in ease of use include a slippery coating on the outer and or inner diameter such as MDX (silicone) or a hydrophilic layer to allow easy access to tortuous anatomy. It may be necessary to utilize a balloon to radially expand the device to its final diameter and location so an inflation lumen and balloon placed distal to the hub could be used. This balloon could be used to pre-dilate the vessel or ostium where the valve may be implanted. Finally elements to transmit signals externally could be imbedded into the catheter for pressure and flow readings or Doppler information. These may include electrical wires, pressure portal or lumens optical fibers.
[0047] As illustrated in FIGS. 1-4 , delivery of the device 18 via catheterization of the implantation site will include a mechanism to deploy or expel the device 18 into the vessel or atrium. This mechanism may include push or pull members 20 and 21 to transmit forces to the distal portion of the catheter 10 . These forces may be applied externally to the body and utilize a handle 22 at the proximal end 12 of the catheter. Means to transmit forces to the distal end 14 may also include a rotational member 24 to loosen or tighten, convert a torque 26 into a translational force such as a threaded screw 28 and nut or to add or subtract stiffness to the catheter 10 or device 18 . The handle 22 mechanism may also include a port for hydraulic pressures to be transmitted to the distal portion of the catheter 10 or have the ability to generate hydraulic forces directly with the handle 22 . These forces may include a pushing or pulling transmitted to the device 18 or catheter 10 , an exposure of the device 18 to allow for implantation or to expel the device 18 from the catheter. Further forces may include a radial or longitudinal expansion of the device 18 or catheter 10 to implant or size the location of implantation. The handle 22 may also include connections to electrical signals to monitor information such as pressures, flow rates, temperature and Doppler information. Another important use of the handle 22 and catheter 10 is the deployment mechanism for the device 18 . As the device 18 is navigated to the site, attachment between the device 18 and catheter 10 is essential. Many detachment methods have been used to deploy devices 18 such as stents and embolic coils through balloon expansion and simple pushable coils expelled from the distal end 14 of a catheter 10 . The valve device can utilize many different methods to implant at the selected site such as an expulsion out the end of the catheter 10 , a mechanical release mechanism such as a pin joint, unscrewing the device 18 from the catheter delivery system, a tethered link such as a thread or wire, a fusible link as used in a GDC coil deployment, a cutting tool to sever a attachment of the device 18 from the catheter 10 , a threaded knot to tether the catheter 10 to the device 18 where the as the knot could be untied or cut, a hydraulic mechanism to deploy, expand or fracture a link between the catheter 10 and the device 18 . All above mentioned concepts may be enhanced be the utilization of a flexible tip to allow acute articulation of the device 18 and delivery catheter 10 to gain access to the implantation site.
[0048] After the device has been temporarily deployed or positioned, it may be advantageous to recapture or reposition the device for optimal results. This may include a rotational or translation of the implant of a complete removal and exchange for a different diameter, length or style device. Capture of an implanted device may require a second catheter to reengage the device to remove or reposition to a proper location.
Valve
[0049] As illustrated in FIGS. 5-8 , in the preferred embodiment the device, such as a valve 30 , would be located between the right lung 31 a and/or left lung 31 b and the left atrium 32 in the right superior pulmonary vein 34 a , the right inferior pulmonary vein 34 b , the left superior pulmonary vein 34 c , the left inferior pulmonary vein 34 d and/or in the wall of the left atrium 32 . Preferably the valve 30 described above is located to affect the flow and pressure of blood between the pulmonary veins 34 a - d and the left atrium 32 or a portion of the left atrium 32 and to lessen the symptoms of mitral regurgitation from a dysfunctional mitral valve 36 including elevations and fluctuations in the pulmonary circulation. The device 30 may be viewed as a one-way valve limiting or restricting retrograde flow into the pulmonary circulation. Having a substantial fatigue life to withstand cyclical operation for a given period of implantation duration will be a factor in selection of both materials and construction. This may include heat treatments to certain portions or all components of the device 30 and analysis of construction and manufacturing techniques to optimize device 30 life. Additionally a coating may be required to maintain patency of the device 30 during normal operation. This may be a surface modification or treatment, a coating added to the device 30 such as heparin or and albumin layer.
[0050] The valve could be a valve of any design including bioprosthetic, mechanical or tissue valves. Examples of commonly used prosthetic valves include a ball valve 40 illustrated in FIG. 9A such as a Starr-Edwards, a single leaflet valve 50 illustrated in FIG. 9B such as a Bjork-Shiley valve, a bileaflet or bi-disk valve 60 illustrated in FIG. 9C or an artificial tricuspid valve such as a Magna or Cribier, a reed style valve 70 illustrated in FIG. 9D , a slit in a membrane of material, a duckbill style or many other styles unmentioned here but apparent to one skilled in the art. To facilitate delivery of the valve and to improve hemodynamics other mechanical valve designs may be utilized, including the poly-leaflet valve and flexible leaflet valves as described below. The valves may be deformable to allow for percutaneous delivery or rigid to enable structural integrity. They may include one of the below mentioned features or a combination of a plurality thereof to add performance and or reduce size.
Mechanical
[0051] As illustrated in FIG. 9A , the early valve implants began in the early 1960's with ball valves 40 such as the Starr-Edwards. This valve 40 includes a base 42 and mechanical structure 44 where a ball 46 is captured and allowed to travel longitudinally sealing flow in one direction and allowing flow in the other. The movement of the ball 46 is driven by flow.
[0052] As illustrated in FIG. 9B , disk style valves 50 , known as Bjork-Shiley, entered the market in the 1970's and began with a single disk 52 supported in a ring 54 where the disk 52 was allowed to pivot within the ring 54 allowing flow in one direction and sealing flow in the other. The tilt angle ranged from about 60-80 degrees.
[0053] As illustrated in FIG. 9C , bi-disk valves 60 include two tilting disks to allow for greater flow and less turbulence. These valves 60 were introduced in the 1980's and seem to be the standard choice.
[0054] As illustrated in FIG. 9E , also disclosed is a poly-leaflet valve 80 for implantation in the body. The valve 80 would contain four or more leaflets 82 free to pivot near the annulus 84 of the valve 80 . Increasing the number of leaflets 82 allows the valve 80 to collapse to a smaller diameter, for percutaneous or minimally invasive delivery, while also providing good hemodynamics, and allowing the leaflets 82 to be made from a rigid material ideally one that has clinically proven good biocompatibility in valve applications.
[0055] Also disclosed is a flexible leaflet valve for implantation in the body. A mechanical prosthetic valve manufactured from a flexible material such as a polymer or tissue material that allows the leaflets to be substantially deformed during delivery if the valve. The leaflets could also consist of metal or a polymeric coated sub straight. If metallic the leaflet material could be a super elastic alloy such as Nitinol or an alloy with a relatively high yield stress and relatively low modulus of elasticity such as certain titanium alloys. Someone skilled in the art will understand the relationship between elastic modulus and yield stress; in order to select materials with a maximum amount of strain available before yielding begins. This would allow for recoverable deformation during delivery and may enhance fatigue characteristics.
[0056] A valve that functions as an iris could also be utilized as a prosthetic valve. The iris could be opened and closed by an internal or external force, a differential in pressure or by the flow of blood.
Tissue
[0057] There are several types of tissue valves that have been previously implanted as replacement valves in the human coronary system. These include valves from human cadavers, and valves from other mammals such as pigs horses and cows utilizing sometimes pericardial tissue to build a valve by sewing techniques. Any of these types of valves could be implanted as described both in a surgical procedure or a catheterization. Additionally other valves such as from the larger venous vessels from smaller animals could be utilized because of the smaller size and reduced flow requirements of the pulmonary veins.
[0058] A valve from the patient may also be used, by transplanting the valve into a pulmonary vein. Many native valves could be used such as a venous valve from the lower extremities. The preferred embodiment is to use a native valve from a large peripheral vein.
Orifice
[0059] The flow control device could be an orifice of fixed or adjustable diameter that limits the amount of blood that flows through the pulmonary veins. The orifice diameter could be adjusted remotely or by some hemodynamic mechanism such as pressure or flow differential or pressure change.
Flap
[0060] The flow control device could consist of one or more flaps located within the atrium to prevent the back flow of blood into the pulmonary veins. The flow control device could be a pivoting or flexible flap that moves to block the ostium of one or more pulmonary veins or it could be a rigid or semi rigid flap or flaps that control the bloods flow path reducing or eliminating the backwards flow of blood in to the pulmonary veins.
Flow Controlled
[0061] In the preferred embodiment the flow through the valve is flow controlled. To the extent possible flow is allowed only in a first direction and not in a second direction. The first direction is intended to be away from the lungs and towards the heart.
Pressure Controlled
[0062] The valve may function such that it is pressure controlled that is it opens at a preset pressure differential. The pressure control could be implemented in several ways. The one-way valve could allow flow in the backward or restricted direction at a certain pressure differential. This may be advantageous in preventing the overloading of the atrium. Alternatively the valve could be designed to open in its normal flow direction at a preset pressure differential.
Metallic
[0063] The valve or flow control device may be manufactured partially or completely from metallic components. Depending on the mechanical properties required various biocompatible metals might be chosen. These include, but are not limited to various stainless steel alloys, cobalt-chrome-nickel-alloys, super-elastic alloys such as Nitinol, Tantalum and titanium and its alloys. The device could be self-expanding in nature if desired.
Polymer
[0064] The valve or flow control device may be manufactured partially or completely from polymeric components. Various biocompatible polymers may be used depending on the desired mechanical properties. Some examples of biocompatible polymers include silicone, polyethylene and, flouropolymers such as Teflon.
External Cuff
[0065] All or part of the flow control device may attach to the outside of the pulmonary vein by applying external force to the vein the device affects the flow through the vein. Both compressive or expansive forces could be applied to change the vessel geometry. An external portion of the device located around the vein may also help to secure a second portion of the device within the vein.
Electrical
[0066] Valves may be actuated to synchronize with the proper opening and closing times through an internal or external device such as a pacemaker. There may require an actuation device to drive the motion of the valve open and closed. Pressure gradients could be used to sense when actuation is necessary.
Vane
[0067] The flow control device may include a vane that introduces a swirling motion to the blood. The vane may be used to improve hemodynamic flow through another portion of the flow control device or it may be used alone to improve the hemodynamics of the native anatomy. The vane may additionally function or rotate in a single direction only to limit flow.
Pump
[0068] In one embodiment the flow control device located between a portion of the pulmonary veins and the heart consists of a pump. The pump may be powered externally, internally or by the biological movement of the heart. The pump may be located inside the pulmonary vein inside the atrium outside the heart or, outside the body.
Inflatable Support Structure
[0069] As illustrated in FIGS. 9F , 9 G, 9 H and 11 , certain pulmonary vein valves in accordance with the present invention include an inflatable support structure 90 , as is disclosed, for example, in the context of an atrial valve, in the provisional applications incorporated by reference above.
[0070] As illustrated in FIGS. 9F and 11 , the inflatable support structure 90 comprises at least one annular ring 92 , such as an annulus for a valve, which is releasably carried by a deployment catheter having at least one inflation lumen extending therethrough. Following positioning of the valve in the pulmonary vein, the annulus is inflated to the desired size and/or pressure, and thereafter decoupled from the deployment catheter. A one way valve 102 on the inflatable support structure 90 prevents escape of the inflation media and/or allows inflation of the inflatable support structure 90 . The one way valve 102 can be a ball valve, as illustrated in FIG. 11 , or another type of valve such as a duck bill valve, pinch or flap valve. The flow control valve 102 illustrated in FIG. 11 has a spring 103 actuated check ball 104 that seals off the inflation lumen 105 . A push wire 106 in the delivery catheter 107 can be used to displace the check ball 104 from the default sealing position, thereby unsealing the inflation lumen 105 and permitting the inflatable support structure 90 to be inflated. Release tangs 108 can be used to secure and align the delivery catheter 107 with the flow control valve 102 .
[0071] As illustrated in FIGS. 9G and 9H , in certain embodiments, the first inflatable chamber 92 is provided such as at the annulus of the valve 90 , and at least a second inflatable chamber 94 is provided, such as to provide commissural support and/or to stabilize the valve 90 , depending upon the occluder (i.e. leaflet) configuration as will be appreciated by those of skill in the art in view of the disclosure herein. In one embodiment, a first inflatable ring 92 is provided at a proximal end 96 of the tubular valve 90 , a second inflatable ring 94 is provided at a distal end 98 of the tubular valve 90 , and at least one additional inflatable chamber 100 is provided in between the proximal and distal ends 96 and 98 , to provide intermediate support. The intermediate support chamber 100 may comprise any of a variety of configurations, such as a zig-zag configuration around the circumference of the valve support structure. A tissue valve or a synthetic leaflet valve may be secured within the tubular valve support structure 90 .
Prosthetic Atrium
[0072] As illustrated in FIG. 10 , in one embodiment the device 110 , such as a valve, is located substantially outside the heart 112 . The the right superior pulmonary vein 114 a , the right inferior pulmonary vein 114 b , the left superior pulmonary vein 114 c and the left inferior pulmonary vein 114 d are spliced into and connect together into a prosthetic atrium 116 . Blood is then directed through a one-way valve 110 and through a conduit 118 to the left ventricle 120 . The native mitral valve could be surgically sealed off and/or the native pulmonary veins 114 a ′- d ′ could be sealed, restricted, occluded, or cut, near where they connect to the left atrium 122 . This procedure could be performed in an open surgical procedure or in a minimally invasive procedure or percutaneously, ideally the procedure would be performed on a beating heart possibly using a thorascope.
[0073] In the preferred embodiment where the procedure is performed on a beating heart 122 , the prosthesis 116 is first flushed and filled with a biocompatible fluid such as saline to prevent the possibility of an air embolism. Next the outlet conduit 118 is attached to a portion of the native anatomy, preferably the left ventricle 120 , and preferably near the apex of the heart 112 . The one way valve 110 portion of the implant prevents blood from the left ventricle 120 from escaping uncontrolled. As a next step a pulmonary vein 114 a - d is cut. The atrium 122 side of the vein 114 a ′- d ′ is tied off or otherwise sealed. The section of the pulmonary vein 114 a - d connected to the lungs is attached to one of the inlet conduits 124 a - d of the prosthesis 116 . In a similar fashion the remaining pulmonary veins 114 a - d are connected to the prosthesis 116 , preferably one at a time.
[0074] In one embodiment the prosthetic atrium is supplied as a chamber with single outlet conduit 118 and four inlet conduits 124 a - d . A one way valve 110 is supplied, attached either to the chamber or in the outlet conduit 118 . Alternatively the outlet conduit 118 may be designed to allow the insertion and attachment of an available prosthetic valve 110 during the procedure. In one embodiment the prosthetic chamber is constructed from a woven fabric, such as polyester. In another embodiment the chamber is constructed from animal tissue such as the aortic root of a pig or the pericardial tissue from a cow. These tissues may be fixed using techniques common in the industry, such as glutaraldehyde fixation.
[0075] In a similar embodiment the blood is directed from the pulmonary veins, into the prosthetic atrium, past the prosthetic valve and then into the native atrium.
[0076] The prosthetic atrium could be of any volume, from as small as is practical to larger than a native atrium. The compliance of the prosthetic atrium is also a variable that may be adjusted to achieve optimal hemodynamics and to limit pulmonary edema.
[0077] In another embodiment the pulmonary veins are interrupted and blood is channeled from the portion of the pulmonary vein nearest the lung, through a prosthetic valve and then back into the portion of the pulmonary vein nearest the atrium. A valve could be placed in one or more pulmonary vein. Alternatively multiple veins could be joined to channel blood to a single valve. The flow of blood could then return to the heart in a single conduit or could be bifurcated into multiple channels and return to the heart, ideally through the ostium where the native pulmonary veins met or meet the atrium.
[0078] In yet another embodiment the valve is located substantially within the pulmonary veins or the atrium, but the valve is inserted through a slit cut into the pulmonary veins. It is possible that by interrupting flow in less than four of the pulmonary veins and or by a rapid surgical procedure, the use of a heart lung machine would not be required to oxygenate the patients blood.
Location
[0079] Location between the lungs and left atrium within the pulmonary veins will allow for single direction flow and protect the lungs from unwanted elevation in pulmonary pressures and fluctuation. The device could be implanted at any location within the pulmonary vein and may allow additional compliance if implanted deep into the pulmonary vein. This may allow the vein to dilate during higher pressures relieving pressures seen in the left atrium or pulmonary circulation. Additionally, an accumulation or expansion chamber may added to the pulmonary vasculature to allow for pressure variations. This device could be adjusted or calibrated to the correct or ideal pressures as normally seen in a healthy human and translate them to the pulmonary circulation. Another device may be located in the left atrium and consist of a bladder containing a fluid such as a gas to relieve excess pressures seen within the left atrium.
[0080] In one embodiment the device is located in the pulmonary veins near or at the ostium where the veins empty into the left atrium. The valves could be placed in this location by many methods including surgically or percutaneously delivery.
[0081] In another embodiment the device is located further up the pulmonary veins closer to the lungs. This location could effectively produce a more compliant and larger volume atrium than the previous embodiment.
[0082] In another embodiment the valve is located substantially within the atrium. With this valve location it may be possible to fit a larger valve for improved hemodynamics, or to allow the valve to cover the flow from more than one pulmonary vein. This may also aid in anchoring the device securely.
Anchoring Methods
[0083] The flow control device can be secured in the anatomy by several methods. As illustrated in FIG. 6 , in one embodiment a portion of the device 30 consists of an expandable stent like structure 38 utilizing an interference fit or surface friction to hold the device 30 in place. The stent like structure 38 could be made from a malleable alloy such as a stainless steel of suitable alloy and condition or cobalt-chromium for better visibility under fluoroscopy. The stent like structure 38 would then be expanded mechanically by a balloon or other means, producing interference fit with the tissue. Alternatively the stent like structure 38 could be one of a self-expanding design, manufactured from a super elastic material such as Nitinol, or a material with a large amount of elastic strain available such as the ellgilloy used in the wall stent. The stent 38 could be manufactured from a tube selectively removing portions with a laser or EDM thus providing optimal expansion and cross-sectional profiles. One skilled in the art of stent design and manufacture could produce many variations of an embodiment as such.
[0084] Another anchoring method is to suture the valve portion to the wall of the atrium or to the pulmonary vein. The flow control device may contain a sewing ring to allow sutures to be easily attached to the device. A percutaneous or minimally invasive sewing device may also be incorporated. This device would contain at least one needle remotely actuated to attach the valve to the tissue, or to a second device previously implanted at the desired valve location. Other methods may utilize a balloon or other force mechanism to push or pull the suture into position.
[0085] Another anchoring method is to staple or clip the valve in place with multiple detachable staples, clips, barbs or hooks. This could be accomplished surgically with a tool that spaces the clips around the annulus and allows them to engage the tissue and a portion of the valve. The staples, clips, hooks or barbs could also be delivered percutaneously with a device that positions the staples, clips, hooks or barbs relative to the valve. These could be attached through a balloon or other force mechanism to push or pull them into position.
[0086] Another anchoring method is to use an adhesive to secure the valve to the tissue. Adhesives such as a fibrin glue or cyanoacrylate could be delivered percutaneously or surgically to attach the valve to the tissue.
Size Range
[0087] The devices could be made in a variety of diameters to correspond to the various anatomy of the patient population. The ideal size of the flow control device designed to be located inside a pulmonary vein may not directly correspond to the diameter of the vein. For example in some cases an oversize valve may be preferred because it may offer better hemodynamics or other advantages. In other cases an undersize valve may be preferred because it may offer reduced vessel trauma or other advantages. The average size of the pulmonary veins is approximately 15 mm in diameter. These valves would preferably be manufactured in a range of sizes from 3 to 30 mm in diameter, although other sizes may be used.
[0088] A flow control device designed for location in the atrium may have a range of sizes significantly larger than the previous embodiment these valves may preferably range from 8 to 80 mm in diameter, although other sizes may also be used.
[0089] A flow control device designed to be located substantially outside the heart and outside the pulmonary veins may include a valve of a range of diameters from 8 to 80 mm.
[0090] An orifice type flow control device if located in the pulmonary vein would require an outside diameter corresponding to the diameter of the vein. The inside diameter would depend on the desired effect on flow. The outside diameter would preferably be approximately 10-20 mm in diameter and may range from 3 to 30 mm in diameter. Other sizes may also be used. The internal diameter of the orifice may range from 1 to 20 mm in diameter. An orifice designed to limit flow through the native arteries when a secondary path for blood flow is provided may be smaller still. In this case an orifice from 0.5 to 5 mm is preferred, although other sizes may be used.
[0091] Length of device may vary depending upon the style selected. Disk style devices may range in length from 2-20 millimeters where a ball-cage style may range from 2-30 millimeters in length. It is also possible to implant a plurality or devices into one vessel for additional performance. The valve portion of the implant may be located distal, proximal or coaxial to the anchoring portion of the device. The anchoring potion of the device may range in length from 2-30 millimeters.
Congenital Defects.
[0092] Devices of similar or identical design could be used to treat patients with congenital defects. For example a patient with a common atrium, where the septal wall between the left and right atrium is missing could be treated with a device described above, although the patient does not have a left atrium the common atrium serves its function and a similar device could be effective. In another example a patient suffering from a transposition of the great cardiac veins could be treated with a similar valve.
Procedure
Cath-Lab
[0093] The procedure is preferably performed in a cardiac catheterization lab, where the normal tools associated with interventional cardiology are available. Many of the conventional tools could be used for the implantation of a valve controlling the flow through the pulmonary veins. These tools include items such as introducers guide catheters, and guide wires may be used with this device. Some devices specifically designed for the valve implantation such as special sizing tools to measure diameters and flow characteristics and access tools to engage the pulmonary veins may be used. A guide catheter with a special curve or curves may be required to access the atrium and pulmonary veins. The device is to be implanted using fluoroscopic guidance or other visualization means such as CT or MRI. A contrast media such as barium sulfate may be used to visualize the coronary anatomy. Contrast could be injected into the pulmonary artery, or one of its branches, to help visualize where the pulmonary veins exit the lungs. Contrast could also be injected from the tip of the guide catheter when engaged into the pulmonary vein to image the ostium clearly for device placement.
Surgical Suite
[0094] Another method of implanting the valve between the pulmonary veins and the heart is a surgical approach. This procedure is to be performed in a surgical suite. The heart may be exposed by a sternotomy or lateral thoracotomy or through a portal entry or the procedure is performed through a puncture or small incision utilizing a minimally invasive tube like device.
[0095] In one version of the procedure the aorta is cross-clamped and the heart is infused with a cardiopelegic solution. A bypass pump is utilized to provide oxygenated blood to the body especially important organs such as the brain.
[0096] In another version surgical tools are utilized to allow the procedure to be performed through small incisions in the heart, preventing the need for the use of the bypass pump, and minimizing the risk of associated complications.
[0097] The valves can be placed in any location that allows the control of blood flow to the atrium from the pulmonary veins and prevents or minimizes back flow. The valves could be placed in the pulmonary veins. This offers advantages for percutaneous placement because the system would use multiple valves of smaller diameter. The valves could also be placed inside the atrium this offers the advantage of possibly implanting larger valves that could control the flow of blood from one or more pulmonary vein. The valves could also be positioned in the ostium of the pulmonary veins; this provides similar advantages to implanting the valves in the pulmonary veins but has the advantage that the tissue may be easier to secure the device to. The valve or valves could also be located outside the heart and the blood flow routed through the valve or valves in a prosthetic conduit.
Entry Vessel
[0098] In the percutaneous procedure access to the pulmonary veins may be gained by a puncture into the venous system and a trans-septal puncture from the right atrium into the left atrium. In this case access to the venous system is gained by a puncture into a vein, preferably the internal jugular vein or the femoral vein would be used, but other veins are also suitable.
[0099] Alternatively in the percutaneous procedure access to the pulmonary veins may be gained, by a puncture into the arterial system. In this case the puncture is preferably performed in the femoral radial or brachial artery although other arteries may be used as well. The catheter is then advanced into the aorta, past the aortic valve, past the mitral valve and into the left atrium where it can access the pulmonary veins
Imaging/Monitoring
[0100] During the procedure or during patient selection, or follow-up, various imaging techniques can be used. These include fluoroscopy, chest x-ray, CT scan and MRI.
[0101] During the procedure or during patient selection, or follow-up, various flows and pressures may be monitored, or example echocardiography may be used to monitor the flow of blood through the pulmonary veins, and other chambers and conduits of the coronary system. It may be especially important to visualize regurgitant flow in the pulmonary veins and past the mitral valve. Additionally pressures may be monitored in various chambers and conduits of the heart; for example pulmonary wedge pressure may be an important measurement.
On or Off Pump
[0102] The surgical procedure may be performed on a cardiac bypass pump. This would allow the device to be implanted with the heart stopped and may not require a cross-clamp of the pulmonary vein. Alternatively using some of the devices and concepts described the surgical procedure may be performed off pump. While maintaining a beating heart, the operation may be performed by using a cross-clamp method to isolate a pulmonary vessel using two clamps to halt the blood flow between the site implantation. A slit or incision may then be made to insert the valve device into the vessel. Alternatively, a complete separation of the vessel between the two clamps and exposing the lumen could be made to implant the valve device. Both techniques would require a suture or reattachment of the vessel post implantation and a suture or other means may be required to maintain proper valve location within the vessel. The techniques of implantation of the device would apply to on-pump implants as well.
Second Atrium
[0103] In an alternative surgical procedure, preferably performed on a beating heart. This procedure utilizes a device that consists of a conduit approximately 20 mm in diameter and a prosthetic valve located in the conduit. The end of the conduit that allows out flow is grafted into the left ventrical. The one-way valve prevents blood from escaping. The pulmonary veins are then transplanted from the left atrium to the inlet side of the conduit. The small portion of the pulmonary veins remaining on the atrium are closed surgically. | An implantable prosthetic valve for a human heart is disclosed. The prosthetic valve has an inflatable tubular annular support structure and at least one moveable occluder that controls the flow of blood through the support structure. The support structure has a flow control valve configured for coupling to an inflation lumen for inflating the support structure with an inflation media. The flow control valve seals after decoupling from the inflation lumen and prevents the inflation media from escaping. | 0 |
FIELD OF THE INVENTION
The present invention relates to an improved process for the preparation of non-hazardous brominating reagent. This invention particularly relates to the preparation of brominating reagent from the alkaline intermediate bromide-bromate mixture obtained from bromine recovery plants. The reagent so obtained is convenient to handle, non-hazardous, easy to transport and can be effectively used in the preparation many aromatic bromo compounds.
BACKGROUND OF THE INVENTION
Liquid bromine is used to prepare a variety of brominated compounds through substitution reactions. This includes commercially important products such as i) tetrabromobisphenol-A (TBBPA)—a flame retardant, ii) eosin—a pigment used in personal care products, iii) bromoacetanilide—an analgesic and antipyretic agent, iv) tribromophenol—an intermediate used in the manufacture of antiseptic, germicide, fungicide, fire extinguishing fluids, fire retardant. and v) 2-bromo-4-nitro acetanilide—a drug intermediate used in the preparation of nimenslide. However, liquid bromine is hazardous by nature and requires extreme care in its production, transportation, and utilization. Besides this, special equipments are required to handle liquid bromine. Moreover, for substitution reactions depicted by equation 1, half of the bromine atoms end up in the effluent as hydrobromic acid.
R—H+Br 2 →RBr+HBr (1)
where R=aromatic substrate.
Reference is made to Survey of Organic Syntheses , Published by Wiley-Inter Science, New York, 1970, Chapter 7 by C. A. Buechler and D. E. Pearson who have reported the preparation of tribromophenol by the interaction of phenol with liquid bromine in a liquid phase. In this process more than 50% of bromine atom ends up as hydrobromic acid as byproduct. The main drawback of this method is the use of hazardous and corrosive liquid bromine. Further, it requires special equipments for handling the liquid bromine. The atomic efficiency of liquid bromine is only 50 percent.
U.S. Pat. No. 5,475,153 (1995) to S. Armstrong discloses the preparation of tetrabromobisphenol-A by reacting bisphenol-A with liquid bromine. Here, hydrogen peroxide was used as oxidizing agent to oxidize hydrobromic acid formed as byproduct to liberate bromine which will react with the unreacted bisphenol-A. The main drawback of this process is the use of hazardous and corrosive liquid bromine. Moreover, the addition of oxidizing agent will increase the unit operations as well as the reaction time.
Z. E. Jolles in his book entitled Bromine and its Compounds , Published by Ernest Benn Ltd., London, 1966, p 394 have reported the preparation of 3-bromomethyl-thiophene by adding 2 moles of N-bromosuccinimide to a separately prepared solution of (i) 2.24 moles of 3-methyl-thiophene; (ii) 0.0165 moles of benzoyl peroxide in 700 ml dry benzene and keeping the reaction mixture under stirring at reflux conditions. In this process, prior to recovery of the product by distillation of benzene, the reaction mixture after complete addition of succinimide is cooled below 5° C. The drawback of this process is that the reagent, N-bromosuccinimide is prepared using liquid brimine at temperature below 5° C. in highly alkaline solution. Cooling of reaction mixture below 5° C. also makes the process cost-intensive. Liquid bromine is corrosive and requires special device to handle it. Besides, benzene is carcinogenic and its recovery by distillation makes the process complicated and needs special care.
Brominating agents that are easy to handle are known but are used mainly for more selective transformations or those where bromine is less effective. A. Groweiss in Organic Process & Development 2000, 4, 30-33, discloses the preparation of active brominating species. In this process a strong acid viz. H 2 SO 4 is slowly added to a stirred aqueous solution or slurry of the reagent containing stoichiometric quantity of sodium bromate and deactivating substituents like nitrobenzene; benzoic acid; benzaldehyde, 4-nitrofluorobenzene and 4-fluorobenzoic acid, while maintaining the temperature in the range of 40-100° C. The drawback of this process is that sodium bromate is costly and its use cannot be justified in more conventional bromination reactions that can be affected by liquid bromine as such. Moreover, the use of sulphuric acid and deactivating substituents are more prone to health hazard, at high temperature. Sulphuric acid is also corrosive in nature.
P. C. Merker et al ( J. Chem. Ed. 26, 1949 p 613) have disclosed the preparation of p-bromoacetanilide by separately preparing a solution of acetanilide (0.232 moles) in cold glacial acetic acid and reacting this solution with pyridiniumbromideperbromide (0.12 moles) in 40 ml hot glacial acetic acid. The resultant mixture was allowed to stand for 30 minutes at room temperature, and then 2 ml of saturated sodium bisulfite solution was added to aqueous solution. The resulting mass was filtered, washed with water and finally recrystallized from hot 95% aqueous ethanol to yield p-bromoacetanilide. The drawbacks of this method are that the brominating agent requires liquid bromine and hydrobromic acid in its preparation which are corrosive and difficult to handle. (L. F. Fieser and M. Fieser, Reagents for Organic Chemistry Vol. 1, John Wiley, New York, 1967, p967) The reagent is costlier than liquid bromine. It involves multi steps making the process less cost benefit
G. Rothenberg and J. H. Clark in Organic Process & Development 2000, 4, 270-274, have disclosed the catalytic bromination of aromatic compounds using alkali bromide or hydrobromic acid and hydrogen peroxide in the presence of 1-2 mol percent vanadium pentoxide catalyst. The drawbacks of this method are that more than stoichiometric quantities of hydrogen peroxide are required and the reaction needs a catalyst. Such catalytic protocols, in general, have several shortcomings like oxidative instability, high purification cost, strict pH and temperature controls. Besides, these reactions require stoichiometric amounts of metal to ensure satisfactory activity.
U.S. Pat. No. 5,817,888 (1998) to H. Y. Elnagar discloses a bromination process wherein organic compounds were selectively brominated in the para-position in high purity and yield. In this bromination process bromine chloride solution was used as brominating reagent which was slowly added at a controlled rate to a solution of aromatic compound maintained at a temperature around 0-4° C. under stirring. At the closure of the reaction, the reaction was quenched with few drops of saturated sodium sulfite solution and then diluted with normal organic solvents. The disadvantages of this method is that the preparation of brominating reagent, bromine chloride, still requires hazardous liquid bromine and chlorine gas under specified conditions.
Pending Application No. PCT/IB02/00386 dated Jan. 25, 2002 to G. Ramachandraiah et al reports the preparation of non-hazardous brominating reagent suitable for aromatic substitution reactions. In this method, calculated amounts of commercially available 4% hypochlorite solution was added to an industrial alkaline bromine mixture and allowed to stand for 24 h for completion of the desired reaction, optionally followed by evaporation to get brominating reagent in solid form. The drawbacks of this process are that, the volumes of hypochlorite solution required to achieve the desired bromide to bromate ratio, is large which unnecessarily increase the process cost or require large containers to handle bromination reactions. The reaction between bromide and hypochlorite and the subsequent reactions are slow as they are highly pH dependent. Further, the hypochlorite solution contains chlorate ions as an integral part in considerable levels, which being a strong oxidizing agent in acidic solutions, may take part in the bromination reactions and produce unwanted side products deteriorating the quality of the product.
OBJECTS OF THE INVENTION
The main object of the present invention is to provide an improved process for environmental benign brominating reagent which obviates the drawbacks as detailed above.
Another object of the present invention is to dispense the use of corrosive liquid bromine in the preparation of brominating reagent.
Still another object of the present invention is to prepare a brominating reagent from an aqueous alkaline bromine intermediate mixture obtained from bromine recovery plant.
Yet another object of the present invention is to increase the bromide:bromate ratio in the alkaline bromine mixture from 5:1 to 2:1 in order to maximize the bromine atom efficiency in aromatic substitution reactions.
Yet another object of the present invention is to provide a method wherein the bromine discharge in the effluent is minimized i.e. <0.5 percent.
Yet another object of the present invention is to purge inexpensive chlorine gas through alkaline bromine mixture that can oxidize bromide ions to bromate ions in alkaline medium to achieve a stoichiometry of 2:1 bromide to bromate ratio in the reagent.
Yet another object of the present invention is to obtain the brominating reagent in solid form which is easy to handle, storage and transport.
Yet another object of the present invention is to carry out the reactions at ambient temperature in the preparation of the brominating reagent of this invention.
SUMMARY OF THE INVENTION
The aim of the present invention is directed to provide an improved process for the preparation of a non-hazardous brominating reagent with active bromine content in the range 45 to 55 weight percent. The alkaline bromine intermediate mixture obtained from bromine recovery plant having bromide to bromate ratio in the range of 4:1 to 5:1 was used. The homogeneous mixture of alkaline bromine was purged with commercial chlorine gas in presence of an alkali. The overall 2:1 molar combination of bromide to bromate was then achieved in it by suitable dilution with fresh alkaline bromine mixture. During the oxidation and dilution process the temperature of the reaction was maintained between 20 to 40° C. The present process is rapid, safe and cost effective giving highly reactive brominating reagent which is easy to handle. The solid product is recovered by evaporation and it obviates the need for any further purification step. This brominating reagent is useful in bromination of various aromatic substrates to prepare organo-bromo compounds.
Accordingly, the present invention provides a process for preparing a non-hazardous brominating reagent by the oxidation of a source of bromide ions to bromate ions, comprising
(i) dissolving an alkali in deionized water; (ii) dispersing the source of bromide ions in 0.5 to 2.0 times v/v of deionized water; (iii) purging chlorine gas or flue chlorine gas to the solution of step (ii) above at a rate ranging from 100 to 1000 ml per minute over a period of 6 to 8 hours or till brown colored vapors are evolved; (iv) diluting the mixture with 2 to 3 times (v/v) of alkaline bromine mixture and the rest deionized water till a clear solution of the mixture is obtained; (v) evaporating the mixture to obtain solid product, and drying the product at a temperature in the range of 55 to 80° C.;
In one embodiment of the invention the mixture of (i) and (ii) is stirred at 300 to 400 rpm in order to dissipate the heat generated during the dissolution of alkali salt.
In another embodiment of the present invention the source of bromide ions comprises an alkaline bromine intermediate mixture obtained from bromine recovery plant having bromide to bromate ratio in the range 4:1 to 5:1.
In another embodiment of the present invention, the alkali comprises caustic soda solution and is added to source of bromide ions in a concentration in the range of 2.5 to 2.8 moles per liter of total source of bromide ions.
In yet another embodiment of the present invention the temperature of the reaction mixture is in the range of 20 to 40° C.
In still another embodiment of the invention, the oxidising agent comprises chlorine gas or flue chlorine gas.
In yet another embodiment of the invention, the oxidizing agent is passed through the mixture of step (ii) at a rate in the range of 100 to 1000 ml per minute.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a process for the preparation of an non-hazardous brominating agent from a source of bromide ions such as an alkaline bromine intermediate mixture obtained from bromine recovery plant.
According to the reaction (2) below, bromide ions can directly be oxidized to bromate ions in an alkaline medium. The acidic protons liberated in this reaction are neutralized (reaction 3) by the alkali present in it.
The final reaction mixture may be evaporated by known techniques to obtain the desired reagent in solid form.
According to the reaction 2 below, bromide ions can directly be oxidized to bromate ions in an alkaline medium. The acidic protons liberated in this reaction are neutralized (reaction 3) by the alkali present in it. The reaction 3 is governed by the quantity of alkali reddish yellow which is characteristic mark for the right conversion of bromide ion to bromate ion to the desired extent.
2Br − +6Cl 2 +6H 2 O→2BrO 3 − +12H + +12Cl − (2)
H + +OH − →H 2 O (3)
In the present invention, the above said reactions were carried out in 5-10 liters round bottom flasks equipped with three necks and a cooling bath if necessary. Here, the alkaline bromine intermediate mixture obtained from bromine recovery plant based on “Cold process” preferably contains from about 18 to 25 wt % of bromide and from about 3 to 7 wt % of bromate and more preferably from about 20 to 22 wt % of bromide and from about 4 to 5 wt % of bromate, was used as a source of bromide ions. The oxidizing agent selected was a commercially available chlorine gas or effluent chlorine gas from any industry for example chlor-alkali industry.
In accordance with this invention, calculated amount of alkali was added to a predetermined volume of alkaline bromine mixture taken in a vessel having stirring facilities and maintaining the temperature at 20 to 40° C. Commercially available chlorine gas was purged through this homogeneous mixture at a regulated flow rate, for a period till brown colored vapours were evolved, while keeping the entire mass under stirring. The required bromide to bromate ratio in the oxidized solution was obtained by requisite dilution with fresh alkaline bromine mixture. Solid and easy to handle brominating reagent was obtained by evaporation of final reaction mixture, followed by drying and grinding to the desired size.
The dissolution of alkali in water is an exothermic reaction. It is thus, necessary to cool the vessel to maintain to room temperature during the preparation of alkali solution.
Since, the rate of bromide oxidation to bromate is fast in concentrated basic solutions, it is preferable to conduct the reaction by dissolving the alkali in minimum volumes of alkaline bromine and deionised water so as to get the required quantity of bromide conversion and then diluting with suitable quantity of original alkaline bromine mixture to adjust the bromide and bromate ratio 2:1.
In the preparation of brominating reagent, the reaction temperature preferably ranges from about to 15 to 75° C. and more preferably are at about ambient temperature (i.e. about 20 to 40° C.). Reaction rates are usually rapid even below ambient temperature and at atmospheric pressure.
The brominating reagent was characterized by determining its bromate and bromide contents by estimating liberated bromine, spectrophotometrically (K. Kumar and D. W. Margerum, Inorg. Chem. 1987, 26, 2706-2711) by measuring the absorbance at 390 nm and using the appropriate molar extinction coefficient (ε, 167 M −1 cm −1 in absence and 522 M −1 cm −1 in the presence of large excess of bromide). The standard iodometric volumetric method (A. I. Vogel A text book of Quantitative Inorganic Analysis, 3rd Ed. Longman, 1962, p349) was followed to estimate for bromate ions and total bromine content.
The present invention relates to the preparation non-hazardous and stable brominating reagent suitable for various applications. This brominating reagent was prepared from alkaline intermediate bromine mixture by oxidation process using chlorine gas at ambient temperature. The water-soluble solid reagent can be efficiently used for aromatic substitution reactions wherein maximum bromine atom efficiency can be achieved. The method of the present invention does not require any special devise and the use of hazardous and corrosive liquid bromine is dispensed. In the present invention alkaline intermediate bromine mixture obtained from bromine recovery plants was utilized to prepare solid brominating reagent having high atom efficiency. The inventive steps adopted in the present invention are (i) preparing non-hazardous brominating reagent from intermediate mixture obtained from bromine recovery plant which obviates the need of liquid bromine; (ii) the reagent is prepared in the ambient temperature (20-40° C.) and does not require cooling below 5° C.; (iii) commercially available and/or flue chlorine gas is used for the oxidation of bromide ion to bromate ion; (iv) the volumes of alkaline bromine mixture is reduced by dispensing the use of other oxidants in solution; (v) dilution is affected using deionized water and the need for organic solvents is dispensed.
The following examples are given by way of illustrations and therefore should not be construed to limit the scope of the present invention.
EXAMPLE 1
Alkaline bromine mixture (1.0 liter) having bromide to bromate ratio 4.4:1 was taken in three necked round bottom flask to which 2.0 liters of deionised water having 13.05 moles of NaOH was mixed at 25° C. under stirring. This reaction mixture was purged with chlorine gas at a rate of 300 ml per minute while maintaining the temperature at 25° C. and continuing the purging of chlorine gas till brown colored vapors were evolved. The passing of chlorine gas was stopped and the reaction mixture was transferred to another vessel where it was diluted with 4.0 liters of alkaline bromine mixture and 0.5 liter of deionised water keeping the entire mass under stirring and continued for another 10 minutes. The solid brominating reagent so formed having bromide to bromate ratio 2:1, was separated by evaporating the water by known techniques and drying the product at 70° C. The active bromine content was found to be 45.3%.
EXAMPLE 2
3.0 liter of alkaline bromine mixture having bromide to bromate ratio 4.4:1 was taken in three necked round bottom flask to which 3.5 liters of deionised water having 26.10 moles of NaOH was mixed at 30° C. under stirring. This reaction mixture was purged with chlorine gas at a rate of 300 cc per minute while maintaining the temperature at 30° C. and continuing the purging of chlorine gas till brown colored vapors were evolved. The passing of chlorine gas was stopped and the reaction mixture was transferred to another vessel where it was diluted with 7.0 liters of alkaline bromine mixture and 0.5 liter of deionised water keeping the entire mass under stirring and continued for another 10 minutes. The solid brominating reagent so formed and having bromide to bromate ratio 2:1 was separated by evaporating the water by known techniques and drying the product at 70° C. The active bromine content was found to be 50.3%.
EXAMPLE 3
3.0 liter of alkaline bromine mixture having bromide to bromate ratio 4.4:1 was taken in three necked round bottom flask to which 3.5 liters of deionised water having 26.10 moles of NaOH was mixed at 38° C. under stirring. This reaction mixture was purged with chlorine gas at a rate of 300 cc per minute while maintaining the temperature at 38° C. and continuing the purging of chlorine gas till brown colored vapors were evolved. The passing of chlorine gas was stopped and the reaction mixture was transferred to another vessel where it was diluted with 7.0 liters of alkaline bromine mixture and 0.5 liter of deionised water keeping the entire mass under stirring and continued for another 10 minutes. The solid brominating reagent so formed and having bromide to bromate ratio 2:1 was separated by evaporating the water by known techniques and drying the product at 70° C. The active bromine content was found to be 50.3%.
EXAMPLE 4
3.0 liter of alkaline bromine mixture having bromide to bromate ratio 4.4:1 was taken in three necked round bottom flask to which 3.5 liters of deionized water having 26.10 moles of NaOH was mixed at 28° C. under stirring. This reaction mixture was purged with chlorine gas at a rate of 900 cc per minute while maintaining the temperature at 28° C. and continuing the purging of chlorine gas till brown colored vapors were evolved. The passing of chlorine gas was stopped and the reaction mixture was transferred to another vessel where it was diluted with 7.0 liters of alkaline bromine mixture and 0.5 liter of deionised water keeping the entire mass under stirring and continued for another 10 minutes. The solid brominating reagent so formed and having bromide to bromate ratio 2:1 was separated by evaporating the water by known techniques and drying the product at 70° C. The active bromine content was found to be 55.0%.
EXAMPLE 5
To 5.0 ml of dichloromethane containing 4-nitroaniline (1 g, 7.246 m mole) in a 250 ml round bottom flask, 1.45 ml of 12 N hydrochloric acid and 10 ml of deionised water were added. To this reaction mixture, brominating reagent containing (2.9 g) of brominating reagent dissolved in 20 ml of deionised water was added slowly under continuous stirring at 28° C. for a period of 30 to 45 minutes. After completion of the addition, stirring was continued for another 15 minutes. The organic layer was separated and extracted with dichloromethane. The organic layer and the organic extracts were mixed and then washed successively with sodium thiosulphate solution and brine. The product, 2,6-dibromo-4-nitroaniline was dried over anhydrous sodium sulphate and concentrated to yield 98.7%. It was characterized by melting point; NMR; IR and elemental analysis.
The main advantages of the present invention are
1. Environmentally benign brominating reagent can be prepared from alkaline intermediate bromine mixture which dispenses the use of liquid bromine.
2. Chlorine gas and/or flue chlorine gas can be used as an oxidizing agent which obviates the need of other costly oxidizing agent, hypochlorite and the impurity, chlorate in it.
3. The bromide ion present in the intermediate mixture can be oxidized at ambient temperature.
4. The aromatic substitution using this reagent can be carried out with high atomic efficiency.
5. This reagent is safe to handle, can be easily transported and preserved. | A cost-effective process is described for the preparation of a stable and non-hazardous brominating reagent containing 2:1 stoichiometric ratio of alkali bromide to alkali bromate. The process comprises of reacting alkaline bromine intermediate mixture, obtained from bromine recovery plant, with chlorine gas in the presence of a strong alkali to oxidize the bromide ions to bromate ions. This brominating reagent is useful for the bromination of aromatic compounds by substitutions. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of Serial No. 10/308,084, which is a continuation of Ser. No. 09/633,264, now abandoned, which is continuation application of U.S. patent application Ser. No. 09/316,013, filed May 21, 1999, which is a continuation application of U.S. patent application Ser. No. 08/793,444, filed May 9, 1997, the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the construction of interior works. More particularly, the invention is concerned with any construction method, involving flat prefabricated elements, especially boards, and at least one joint-pointing coat which can be used especially for the finishing of a joint. The flat prefabricated elements comprise a plaster board and at least one sheet of lining paper, at least one outer layer of which has a visible outer face ready to be decorated. The said flat elements are assembled together, especially with a coat, and the joints are finished with the said joint-pointing coat, so as to obtain an overall visible outer surface which is relatively uniform or plane, including in the region of the joints. Such a method is employed, for example, when plasterboards covered with a cardboard lining having a joint-pointing coat are assembled, for the purpose of defining spaces within a building, especially partitions.
DESCRIPTION OF RELATED ART
[0003] According to the document EP-A-0,521,804, the lining paper may comprise an upper layer, called an upper web, comprising white cellulose fibres, mainly synthetic, and a mineral filler of light colour, preferably white, and a pigment layer covering the upper layer, comprising a mineral filler of light colour, preferably white, and a binder.
[0004] In general the overall visible outer surface obtained according to the above-defined method needs to be prepared, before receiving any surface decoration, such as one or more layers of a film covering of the paint or lacquer type or a wallpaper. This preparation is necessitated especially by the shade or colour differences existing between the visible outer surface of the flat prefabricated elements, for example plasterboards, and the visible outer surface of the joints. After the interior work has been completed, this preparation involves covering the overall surface obtained, i.e. the lining of the flat prefabricated elements plus the joints, with one or more layers of a paint or priming or finishing coat.
[0005] The preparation operation represents an appreciable additional cost, for example in a complete process for the construction of a building. And in some cases, it is still insufficient for obtaining an overall decorated surface of uniform appearance, particularly in view of the physico-mechanical differences prevailing between the joints and the flat prefabricated elements.
SUMMARY OF THE INVENTION
[0006] The object of the present invention is to overcome the abovementioned disadvantages. More specifically, the object of the invention is a construction method breaking with the traditional approach adopted for solving the problem explained above, that is to say avoiding the need for a preparation of the overall surface, before any decoration. However, the object of the invention is a method which remains compatible with the practices of the professionals in the construction industry, especially those involved in interior works.
[0007] According to the present invention, the method differs from the traditional approach in that, the structure and/or composition of the sheet of lining paper and the composition of the joint-pointing coat are coordinated with one another in order, in the dry state of the joint-pointing coat, to obtain an overall surface having one or more physical characteristics, including colour or shade, which are substantially homogeneous in virtually the entire overall surface, including in the region of the visible outer face of the joints.
[0008] According to other objects of the invention a construction assembly for interior works is provided, comprising, flat prefabricated elements, especially boards, and, a joint-pointing coat capable of being used especially for the finishing of a joint. The flat prefabricated elements comprise a plaster body and at least one sheet of lining paper, at least one outer layer of which has a visible outer face ready to be decorated. In this assembly, the structure and/or composition of the sheet of lining paper and the composition of the joint-pointing coat are coordinated with one another in order, in the dry state of the joint-pointing coat, to obtain an overall surface having one or more physical characteristics, including colour or shade, which are substantially homogeneous in virtually the entire overall surface, including in the region of the visible outer face of the joints.
[0009] A joint-pointing coat, intended to be used in the method or the assembly according to the invention, is also provided.
[0010] The present invention affords the following decisive advantages which result from the surface homogeneity of the overall surface obtained according to the present invention, not only in terms of colour or shade, but also in terms of particular physical or physico-chemical characteristics.
[0011] Thus, by homogenizing the surface absorption capacity of the lining paper and of the joint-pointing coat, a virtually perfect appearance of the paint layer or paint layers and a virtually uniform adhesion of a wallpaper can be obtained. This subsequently is conducive to the homogeneous detachment of the wallpaper.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] In a preferred version of the invention, there is a sealing coat intended for forming essentially the joints between the various flat elements, with the joint-pointing coat being a finishing coat which can be applied to the sealing coat.
[0013] According to an advantageous embodiment of the invention, when there are preexisting flat prefabricated elements, the composition of the joint-pointing coat is coordinated with the structure and/or composition of the sheet of lining paper.
[0014] According to another version of the invention, and converse to the foregoing, for a preexisting joint-pointing coat, the composition of the sheet of lining paper is coordinated with the composition of the joint-pointing coat.
[0015] Moreover, the method is more preferably characterized in that, in addition to the colour or shade, at least any one of the following physical characteristics is homogenized or matched between flat prefabricated elements and the joint-pointing coat, namely:
[0016] the surface appearance, including reflectance;
[0017] the absorption of surface water;
[0018] decoloration or coloration under the effect of natural light.
[0019] Advantageously, these various physical characteristics are defined as follows:
[0020] the reflectance factor of the overall surface, including that of the visible outer face of the joints, is between 70% and 80%, and preferably between 72% and 76%, for a wavelength of 457 nm;
[0021] the decoloration or coloration of the overall surface, including that of the visible outer face of the joints, has a colour deviation (delta E*) at most equal to 3 after exposure for 72 hours to a source of UV radiation arranged at 15 cm from the surface and having a wavelength at least equal to 290 nm;
[0022] the surface water absorption of the overall surface, including that of the visible outer face of the joints, is not less than 60 minutes and/or is at most equal to 15 g/m 2 according to the COBB test, at 23° C.
[0023] In practice, and by means of routine tests, the average person skilled in the art knows how to coordinate the structure and/or composition of a sheet of lining paper and/or the composition of a coat, so as to satisfy the above-defined technical principles. As a result, the examples described below are in no way limiting.
[0024] The present invention will now be described by taking flat prefabricated elements, plasterboards, as an example. These boards are typically composed of a factory-cast plaster body between two sheets of paper forming both its lining and its reinforcement.
[0025] Conventionally, one of the sheets of paper used for making the plasterboards has a dark colour which can vary between a grey colour and a chestnut colour, since it is composed of cellulose fibres which have not undergone any particular purifying treatment. Traditionally, this so-called grey paper is obtained from unbleached chemical pulp and/or from mechanical pulp, and/or from thermomechanical pulp and/or from semi-chemical pulp. By mechanical pulp, it is usually meant a pulp obtained entirely by mechanical means from various raw materials, essentially wood, which can be provided by salvaged products originating from wood, such as old cardboard boxes, trimmings of kraft paper and/or old newspapers. Thermomechanical pulp means a pulp obtained by thermal treatment followed by a mechanical treatment of the raw material. By semi-chemical pulp is meant a pulp obtained by eliminating some of the non-cellulose components from the raw material by means of chemical treatment and requiring a subsequent mechanical treatment in order to disperse the fibres.
[0026] The other sheet of plasterboards has a visible face, called a lining face, of a colour generally lighter than the grey sheet. To obtain this lighter colour, the layer or layers of this face are based on chemical pulp, if appropriately bleached, composed of recycled and/or new cellulose fibres, and/or on mechanical pulp, if appropriately bleached. By chemical pulp is meant a pulp obtained by eliminating a very large proportion of the non-cellulose components from the raw material by chemical treatment, for example, by cooking in the presence of suitable chemical agents, such as soda or bisulphites. When this chemical treatment is completed by bleaching, a large part of the coloured substances is eliminated, as well as the substances which risk decomposing by ageing and giving unpleasant yellow shades associated with the presence of, for example, lignin.
[0027] In a preferred embodiment of the method of the invention, and according to the document EP-A-0 521 804, the content of which is incorporated by reference, the lining paper comprises an upper layer, called an upper web, comprising white cellulose fibres, mainly synthetic, a mineral filler of light colour, preferably white, and a pigment layer covering the upper layer. The pigment layer comprises a mineral filler of light colour, preferably white, and a binder. Correspondingly, according to the present invention, the joint-pointing coat comprises a mineral filler of light colour, preferably white, the grain size of which is between 5 and 35 μm.
[0028] The fineness of the grain size of the mineral filler of the joint-pointing coat makes it possible to obtain a smooth surface corresponding to that of the lining of the board. Too large a grain size of the filler gives rise to overall surface defects, such as a reflection of light radiation on the surface of the coat which is different from that on the surface of the board, bringing about differences in tone and brightness of the shade. Too large a grain size also gives rise to differences in physical appearance which are associated with the differences in roughness between the board and the coat.
[0029] The mineral filler represents preferably between 50% and 85% of the total weight of the joint-pointing coat.
[0030] Moreover, the coat can comprise a hydrophobic agent, for example between 0.2% and 5%, and preferably between 0.5% and 3%, of the total weight of the coat, for example a silicone derivative. This agent slows the drying kinetics of the coat, which is conducive to the non-cracking of the coat. Also, this agent has higher resistance to the attack of steam during operations for the removal of wallpaper, so that the removal can be achieved without thereby impairing the good bonding of a paint or paper adhesive on the overall surface, including the visible surface of the joints. In fact, this hydrophobic agent makes it possible to level off the absorbent capacities of the surfaces of the coat and of the lining paper of the board. Thus, all paints or paper adhesives applied to the overall surface obtained exhibit little shift in absorption kinetics between the coat and the board, thus making it possible to avoid the appearance of spectra or of defects in shade homogeneity.
[0031] The coat also comprises an organic binder dispersible in aqueous phase, in a proportion of between 1 and 20%, and preferably between 2 and 12%, of the total weight of the joint-pointing coat, for example polyvinyl acetates and/or acrylic acid esters. The choice of this binder is important, since it must impart sufficient flexibility to the coat to withstand mechanical stresses, and it must have both an adhesive capacity for obtaining a good bond on the overall surface and good resistance to the attacks of UV light.
[0032] Moreover, a handling agent is provided in the composition of the coat, especially a water-retaining and thickening agent, for example methylhydroxyethyl-cellulose, in a proportion of 1 to 15%, and preferably of 2 to 12%, of the total weight of the joint-pointing coat.
[0033] Finally, at least one slipping agent can be included in the composition of the coat, especially a clay, in the proportion of 0.1 to 2%, and preferably of 0.1 to 0.6%, of the total weight of the joint-pointing coat. These clays are preferably silicate derivatives and more preferably clays of the attapulgite type.
[0034] Other components, such as biocides, dispersants, anti-foaming agents and pigments can also be incorporated in the composition of the coat in the conventional way.
[0035] The invention will be understood better from the following detailed example given as a non-limiting indication.
[0036] We proceed from plasterboards similar to Example 5 of document EP-A-0 521 804, which are assembled by means of a conventional sealing joint, for example a joint coat sold under the registered trade mark of “PREGYLYS”® of the Company PLATRES LAFARGE. The upper web of the lining of the board is obtained from 65% bleached synthetic cellulose fibres and 35% talcum and is covered with a pigment layer comprising, as mineral filler, 85% by weight of CaSO 4 , 2H 2 in the form of needles of a length of between 3 and 5 μm and, as a binder, 10.3% by weight of styrene-butadiene copolymer. The sealing joint subsequently receives a thin layer of a joint-pointing coat according to the invention, having the following composition:
[0037] 50 to 85% by weight of calcium carbonate, grain size from 5 to 35 μm, as a mineral filler;
[0038] 2 to 12% by weight of a binder comprising polyvinyl acetates and acrylic acid esters in aqueous dispersion;
[0039] 0.5 to 3% by weight of a silicone derivative as a hydrophobic agent;
[0040] 0.1 to 0.9% of a cellulose derivative of the methylhydroxyethylcellulose type;
[0041] 0.1 to 0.6% of a slipping agent of the attapulgite type;
[0042] 1 to 12% of another silicate derivative as an additional slipping agent;
[0043] 0.1 to 5% of a polycarboxylic acid ammonium salt as a dispersant;
[0044] 0.001 to 0.015 of an iron oxide as a pigment;
[0045] 0.1 to 0.3% of a preparation of N-formoles and isothiazolinones as a biocide;
[0046] 0.1 to 0.3% of a conventional anti-foaming agent; water up to 100%.,
[0047] The weight percentages given are in relation to the total weight of the coat, unless indicated otherwise.
[0048] For comparison requirements, standard boards conforming solely to French standard NF P 72-302 and not comprising the above-defined upper web and pigment layer are assembled by means of a joint coat for a plasterboard of the range of coats “PREGYLYS”®, sold by the Company PLATRES LAFARGE.
[0049] The characteristics of the two overall surfaces thus formed are compared by applying the following tests:
[0050] (A) Degree of whiteness or reflectance factor R obtained according to standard NFQ 03038 with a wavelength of 457 nm. This degree represents the percentage ratio between of a reflected radiation of the body in question and that of a perfect diffuser under the same conditions.
[0051] (B) Surface water absorption obtained, for example, according to the COBB test. In this test, a ring defining an area of 100 cm 2 is filled with distilled water at 23° C. to a height of approximately 10 mm. The water is left in contact with the overall surface forming the bottom of the ring for one minute, and then the water is emptied and the excess spin-dried. The weight gain of the surface is subsequently determined and brought back to an area of 1 m 2 . In an alternative version, a drop of distilled water of a volume of approximately 0.05 cm 3 at 23° C. is deposited on the surface. It is important that the drop be deposited and not allowed to fall from a variable height which consequently would crush it to a greater or lesser extent, thus falsifying the result. The duration in minutes represents the surface absorption of the tested area.
[0052] (C) UV radiation resistance obtained by exposing the overall surfaces, in a cabinet comprising eight high pressure mercury vapour lamps, each of 400 watts, to a wavelength which is not less than 290 nm. The surfaces are maintained at a distance of 15 cm from the lamps and at a temperature of 60° C. for 72 hours. The colour deviations delta E* are measured on a spectro-colorimeter according to the standard DIN 6174 at an angle of 8°, illuminant D65 as a bright specular, included in the system L*, a*, b*, in which L* is the luminance, a* represents the transition from green to red, and b* represents the transition from blue to yellow. A point E* in this system, the said point being a function of L*, a*, b*, defines the colorimetry of a sample and the deviation is measured in relation to a reference point. In general terms, a colour deviation beyond 2 becomes discernible to the naked eye.
[0053] The results of the tests (A) and (B) are collated in Table I and those of the test (C) are collated in Table II below.
TABLE I Overall surface according Standard overall surface to the invention Reflectance R (%) Board: 50 to 60 Board: 72 to 76 Coat: 65 to 85 Coat: 65 to 85 Absorption 19 13 COBB (g/m 2 ) Board: 50 Board: >= 60 Alternative (min) Coat: 15 Coat: >= 60
[0054] This shows that the overall surface according to the present invention is clearly more homogeneous than that of an assembly according to the conventional technique. Moreover, the more homogeneous absorption time of the overall surface makes it possible to use a paint having less covering capacity than that necessary with traditional boards and coats and is also beneficial to the painting operation.
TABLE II Standard Invention Before Exposure Initial measurements of the board L* = 82.94 L* = 90.41 a* = −0.43 a* = −0.03 b* = 4.64 b* = 3.13 Initial measurement of the joint L* = 90.70 L* = 89.70 a* = 0.73 a* = 0.50 b* = 5.28 b* = 3.60 Board/Joint Board/Joint col- Colour devi- our deviation ation delta E* = delta E* = 1 7.87 Exposure to UV for 72 hours Measurements of the board after L* = 81.10 L* = 90.38 exposure a* = 0.69 a* = −0.91 b* = 12.93 b* = 7.40 Colour devia- Colour deviation tion delta E* = delta E* = 4.36; 8.56; very substantial substantial yellowing yellowing plus chestnut spots Measurements of the joint after L* = 88.90 L* = 89.17 exposure a* = 0.91 a* = 0.50 b* = 3.83 b* = 3.19 Colour devia- Colour deviation tion delta E* = delta E* = 0.67; 2.32; slight very slight col- yellowing plus our deviation a few chestnut spots
[0055] This table shows that the colour deviation before exposure to UV is much slighter for an overall surface according to the invention than for an overall surface such as is obtained traditionally.
[0056] This table also shows that the change in the colour deviation after exposure to UV is much less pronounced in the overall surface according to the invention than traditionally. In fact, the colour deviation before exposure and after exposure must be as little as possible, so that the overall surface does not give the impression to the naked eye of being spotted or being covered with zones of different shade and brightness.
[0057] This is not possible with an overall surface obtained by means of traditional plasterboards and products, but the very slight deviation of the overall surface according to the invention makes it possible to mitigate this disadvantage.
[0058] Although only preferred embodiments are specifically illustrated and described herein, it will be appreciated that many modifications and variations of the present invention are possible in light of the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention. | A construction assembly includes a plurality of plaster boards, each of the plaster boards having a plaster body and at least one sheet of liner, the liner including an inner surface attached to the plaster body and an outer surface having an outer face; wherein said plaster boards are assembled creating at least one joint; and a joint-pointing coat jointing said plaster boards to form a substantially plane outer surface including the outer surface of said at least one joint and said outer surface of said liner, wherein the composition of the joint-pointing coat is adapted for the finishing of said at least one joint; wherein both the joint-pointing coat in the dry state and the outer face of the sheet of liner are adapted to form an overall surface having a substantially homogeneous coloration. | 4 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure is related to the field of network traffic management. More specifically, the present disclosure is related to load placement in data center networks.
[0003] 2. Description of Related Art
[0004] As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use similar to financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
[0005] Traditional data center networks include a top of rack (TOR) switch layer, an aggregation switch layer, and a backbone switch layer. In data center networks for data packet routing, data flow is established and forwarded using static hash functions when there exists more than one path to the destination from a switch. Static hash functions do not consider the current load on specific links in allocating the flow through the link. Moreover, static hash functions may be biased as they merely perform regular hash operations on fixed header fields. As a result of such biasing, traffic load through the network links may be highly polarized. Thus, while some links may bear the burden of a high traffic load, other links at the same layer level may have little or no traffic flowing through. This leads to imbalance and inefficiencies in the data center network traffic management.
[0006] In state-of-the-art data center networks a node failure or a link failure typically is resolved by re-routing traffic at a point close to, or directly on, the point of failure. Furthermore, in state-of-the-art data center networks a node failure or a link failure is resolved after a failure notification is sent to a controller or manager, at which point the controller or manager makes the re-routing decision. This failure recovery process is time consuming and results in inefficient re-routing architectures and results in time periods where the traffic is black-holed.
[0007] What is needed is a system and a method for load placement in a data center that uses current traffic information through the links in the system. Also needed is a system and a method to engineer data traffic in order to avoid congested links in a data center network. Further needed is a system and a method for resolving node failure and link failure in a data center network.
SUMMARY
[0008] According to embodiments disclosed herein, a system for operating a plurality of information handling systems forming a network may include a plurality of switches; an open flow controller coupled to each of the plurality of switches; a plurality of links, each link configured to transmit data packets between two switches from the plurality of switches; wherein: the open flow controller is configured to determine a traffic flow across each of the plurality of links; and each one of the plurality of switches is configured to re-route a data packet when the traffic flow in a link associated to the switch exceeds a threshold.
[0009] A computer program product in embodiments disclosed herein may include a non-transitory computer readable medium having computer readable and executable code for instructing a processor in a management unit for a plurality of information handling systems forming a network to perform a method, the method including performing a discovery of the network topology; receiving a load report for a link between information handling systems in the network; determining a flow rate for a link in the network; and computing a label switch path.
[0010] A network managing device according to embodiments disclosed herein is configured to be coupled to a service provider having resources, and to be coupled to a storage component and a computational component to provide a service to a plurality of users through a network may include a link to a plurality of switches; a processor circuit configured to discover a topology of the network, to determine a flow rate for a link in the network, and to compute a label switch path; and a memory circuit to store the label switch path and the topology of the network.
[0011] These and other embodiments will be described in further detail below with reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a data center network, according to some embodiments.
[0013] FIG. 2 shows an open flow (OF) controller coupled to a switch, according to some embodiments.
[0014] FIG. 3 shows a flow chart of a method for load placement in a data center network, according to some embodiments.
[0015] FIG. 4 shows a flow chart of a method for load placement in a data center network, according to some embodiments.
[0016] FIG. 5 shows a flow chart of a method for load placement in a data center network, according to some embodiments.
[0017] FIG. 6 shows a flow chart of a method for load placement in a data center network, according to some embodiments.
[0018] FIG. 7 shows a data center network configured for a node failure recovery, according to some embodiments.
[0019] FIG. 8 shows a data center network configured for a link failure recovery, according to some embodiments.
[0020] In the figures, elements having the same reference number have the same or similar functions.
DETAILED DESCRIPTION
[0021] For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources similar to a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices similar to various input and output ( 10 ) devices, similar to a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.
[0022] FIG. 1 shows a data center network 100 , according to some embodiments. Data center network 100 includes three layers of nodes, or switches. A top-of-rack (TOR) layer 110 includes switches 111 - 1 , 111 - 2 , 111 - 3 , 111 - 4 , 111 - 5 , 111 - 6 , 111 - 7 , and 111 - 8 , collectively referred hereinafter as TOR switches 111 . TOR switches 111 normally are placed on top of server racks at server locations. An aggregation layer 120 may include switches 121 - 1 , 121 - 2 , 121 - 3 , 121 - 4 , 121 - 5 , 121 - 6 , 121 - 7 , and 121 - 8 , collectively referred hereinafter as aggregation switches 121 . A backbone layer 130 may include switches 131 - 1 , 131 - 2 , 131 - 3 , and 131 - 4 , collectively referred hereinafter as backbone switches 131 . Data center network 100 may also include Open Flow (OF) controller circuit 150 . In some embodiments, OF controller 150 configures switches 111 , 121 , and 131 in order to handle the traffic flow through data center network 100 . OF controller 150 is coupled to each of switches 111 , 121 , and 131 in data center network 100 . FIG. 1 shows eight (8) TOR switches 111 , eight (8) aggregation switches 121 , and four (4) backbone switches 131 for illustrative purposes only. One of ordinary skill would recognize that there is no limitation in the number of switches that may be included in each of a TOR layer, an aggregation layer, and a backbone layer. Data traffic in data center network 100 may be unicast (point-to-point transmission). In some embodiments the data traffic may be multicast (single-point-to-multiple point transmission).
[0023] Data center network 100 also includes links between the switches, so that data packets may be transmitted from one switch to the other. The switches shown in FIG. 1 include four ports each, coupled to links. In some embodiments, each of TOR switches 111 may include two ports in the ‘south’ direction, coupling the TOR switches to the servers in a server layer. Also, in some embodiments each of TOR switches may include two ports in the ‘north’ direction, coupling each of the TOR switches with at least two aggregation switches 121 . Likewise, each of aggregation switches 121 may include two ports in the ‘south’ direction coupling each aggregation switch 121 with at least two TOR switches. Also, in some embodiments each of aggregation switches 121 may include two ports in the ‘north’ direction coupling each aggregation switch 121 with at least two backbone switches 131 . In some embodiments, backbone layer 130 may be the top most layer in the data center network. Thus, ports in each backbone switch 131 may couple the switch to four aggregation switches 121 in the ‘south’ direction. The specific number of ports for switches 111 , 121 , and 131 is not limiting of the embodiments of the present disclosure. Furthermore, in some embodiments a switch in any one of TOR layer 110 , aggregation layer 120 , and backbone layer 130 , may include one or more ports in the East or West direction, coupling the switch to at least another switch in the same layer level. For example, link 115 couples switches 111 - 6 and 111 - 7 in an East-West direction in TOR layer 110 . Likewise, link 125 couples switches 121 - 2 and 121 - 3 in an East-West direction in aggregation layer 120 . And link 135 couples switches 131 - 3 and 131 - 4 in backbone layer 130 .
[0024] Accordingly, an ingress data packet in TOR switch 111 - 1 may be transmitted to aggregation switch 121 - 1 through link 160 - 1 . From aggregation switch 121 - 1 , the ingress data packet may be routed to backbone switch 131 - 1 through link 161 - 1 . Backbone switch 131 - 1 may transmit the data packet to aggregation switch 121 - 7 through link 161 - 2 . Aggregation switch 121 - 7 may transmit the data packet to TOR switch 111 - 8 through link 160 - 4 , so that the ingress data packet becomes an egress data packet and is forwarded to the appropriate server below TOR switch 111 - 8 .
[0025] According to some embodiments, link 161 - 1 between aggregation switch 121 - 1 and backbone switch 131 - 1 may have a heavy traffic polarization with respect to link 160 - 2 . Link 160 - 2 couples aggregation switch 121 - 1 and backbone switch 131 - 2 . For example, while link 161 - 1 may carry about nine (9) Gigabit per second (GBs) of data flow, link 161 - 2 may carry only one (1) or less GBs of data flow. Accordingly, OF controller 150 may decide to re-route the ingress data packet from link 161 - 1 to link 160 - 2 , using a re-routing strategy. The decision to re-route the ingress data packet may be triggered when a traffic flow in a link exceeds a pre-selected threshold value. The pre-selected threshold value may be 5 GBs, 6 GBs, or more, according to the number of ports and configuration of the switch supporting the link.
[0026] In embodiments where OF controller 150 uses a multiple protocol label switching (MPLS) configuration as a re-routing strategy, labels 151 - 1 , 151 - 2 151 - 3 , 151 - 4 , and 151 - 5 (collectively referred hereinafter as labels 151 ) are placed in headers of the ingress data packet. Labels 151 include flow identifiers used to establish a route for the ingress data packet through the data center network. In some embodiments, flow identifiers may be included in an N-tuple, in labels 151 . A flow is identified by an associated N-tuple. In some embodiments, an N-tuple may include information such as IP-Source-Address, Destination-IP-Address, Source-Port number, Destination Port-number, and Protocol type. Typically, a flow identifier related to a five-tuple as described above may be used by OF controller 150 for setting up flow information.
[0027] In some embodiments an N-tuple may include a Source Mac-Address and a Destination Mac-Address. Further according to some embodiments, an N-tuple may be a two-tuple including the Source MAC and the destination MAC alone. The contents of an N-tuple may identify traffic flow passing through the router in a given direction, or in both directions.
[0028] Labels 151 may be placed in headers of the ingress data packets by each of the switches receiving the packets. For example, switch 111 - 1 may ‘push’ label 151 - 1 in the ingress data packet in switch 111 - 1 . Label 151 - 1 routes the data packet through link 160 - 1 . Further, aggregation switch 121 may ‘swap’ label 151 - 1 with label 151 - 2 in the data packet header. Label 151 - 2 routes the data packet through link 160 - 2 towards backbone switch 131 - 2 , instead of using link 161 - 1 to backbone switch 131 - 1 . Thus, switch 121 - 1 reduces the traffic load through link 161 - 1 , effectively balancing the load between links 161 - 1 and 160 - 2 . Backbone switch 131 - 2 may ‘swap’ label 151 - 2 in the data packet header with label 151 - 3 , re-routing the data packet through link 160 - 3 towards aggregation switch 121 - 7 . Aggregation switch 121 - 7 may ‘swap’ label 151 - 3 with label 151 - 4 , routing the data packet through link 160 - 4 toward TOR switch 111 - 8 . Switch 111 - 8 may then ‘pop’ or remove label 151 - 5 from the data packet header, and forward the data packet to the intended recipient.
[0029] Accordingly, OF controller 150 may prepare and distribute labels 151 to each of switches 111 - 1 , 121 - 1 , 131 - 2 , 121 - 7 , and 111 - 8 when a load imbalance is detected between links 161 - 1 and 160 - 2 . Thus, a data packet may have a re-routing trace assigned at the point of ingress to the data center network. This strategy reduces the time delay introduced in the data center network for load balancing. Also, embodiments using this strategy are able to distribute traffic flow comprehensively through the data center network. For example, OF controller 150 may use knowledge of the data center network topology to implement a re-routing strategy that results in load balancing in distant nodes.
[0030] FIG. 2 shows an OF controller 250 coupled to a switch 270 , according to some embodiments. OF controller 250 and switch 270 may be as OF controller 150 and any one of TOR switches 111 , aggregate switches 121 , or backbone switches 131 , in data center network 100 (cf. FIG. 1 ). OF controller 250 may include a processor circuit 261 and a memory circuit 262 . Memory circuit 262 stores commands and data used by processor circuit 261 to execute operations on switch 270 , through an OF agent 275 . Switch 270 includes processor circuit 271 and memory circuit 272 . Memory circuit 272 stores commands and data used by processor circuit 271 to perform the tasks of switch 270 . According to some embodiments, the commands stored in memory circuit 272 may be provided by OF controller 250 through OF agent 275 . In particular, in some embodiments OF agent 275 provides an operating system to processor circuit 271 in order to execute the commands stored in memory circuit 272 .
[0031] Thus, OF controller 250 may instruct OF agent 275 to ‘push,’ swap; or ‘pop’ a label on a data packet header in a re-routing configuration using labels 151 , as described in detail above in relation to FIG. 1 . A ‘push’ instruction includes writing a label in the data packet header. A ‘swap’ instruction includes replacing a first label with a second label in the data packet header. A ‘pop’ instructions includes removing a label from the data packet header.
[0032] According to embodiments disclosed herein, switch 270 may be a hybrid switch configured by OF agent to operate in an open flow environment. A hybrid switch may also be configured to perform bidirectional forwarding detection (BFD) sessions with neighbors in a data center network. In a BFD session, switch 270 sends a test packet, or hand-shake packet to a neighbor switch, expecting a return of the packet after a certain period of time. When the hand-shake packet fails to return to switch 270 , switch 270 may determine that the destination switch, or a link to the destination switch, has failed. Likewise, during a BFD session switch 270 may return a hand-shake packet to a neighbor in the data center network. In some embodiments, a BFD session may involve only nearest neighbors, so that the hand-shake takes place across a single-hop. In some embodiments a BFD session may involve a plurality of hops in the data center network. In such embodiments, the BFD session is a multi-hop session where the neighbor with which the BFD session is being run is multiple hops away and not an immediate neighbor. When a failure is discovered during a BFD session, a flag may be raised on OF agent 275 . Thus, OF agent 275 may send a report to OF controller 250 . OF agent 275 may also provide commands to processor 271 in switch 270 without waiting for instructions from OF controller 250 .
[0033] In some embodiments, a BFD session may be run on the switches to detect single hop failures. In some instances a BFD session may detect multi-hop failures. Some embodiments may include pre-built bypass paths for specific links, using BFD sessions. Once the pre-built bypass paths are computed, they may be downloaded to the OF Agent in the switch running the BFD session. Thus, when the BFD session detects failure then bypass paths are installed in the hardware to perform a fast failover.
[0034] In embodiments where switch 270 is a hybrid switch, OF agent 275 may store in memory circuit 272 a fast re-route (FRR) set of paths for re-routing data packets through switch 270 . The FRR set of paths may include links and IP addresses of switches in data center network 100 . According to some embodiments, each path in the FRR set may be associated to switch 270 and to a failed link, a failed switch, or a combination of a failed link and a failed switch. For example, each path in the FRR set includes paths having switch 270 as a node, excluding a failed link coupled to switch 270 , or a failed switch coupled to switch 270 . Furthermore, the FRR set may exclude a combination of a link and a switch coupled to switch 270 , both of which may have a failure at some point in time.
[0035] Data plane programming is done through OF agent 275 in switch 270 . For example, data plane programming may include computing the FRR set of paths by the OF controller. OF controller 250 may in turn pass the FRR set of paths for circuit 270 to OF agent 275 . Thus, by computing the FRR sets the OF controller in a data center network 100 , has a comprehensive image of the traffic architecture across data center network 100 and their respective backup paths.
[0036] FIG. 3 shows a flow chart of a method 300 for load placement in a data center network, according to some embodiments. Some embodiments may deploy an OF controller such as OF controller 150 in data center network 100 (cf. FIG. 1 ). Thus, method 300 may be performed by processor circuit 261 executing commands stored by memory circuit 262 in OF controller 250 . The OF controller may execute operations on the switches and links of the data center network, as described in detail above (cf. FIG. 1 ). In some embodiments, an OF controller deployed in a data center network may be coupled to each of the switches in the data center network through an OF agent such as OF agent 275 (cf. FIG. 2 ). Thus, in some embodiments steps in method 300 may be partially performed by a processor circuit in some OF agents in the data center network, upon configuration by the OF controller. The processor circuit coupled to an OF agent in a switch may be similar to processor circuit 271 , performing commands stored in memory circuit 272 (cf. FIG. 2 ).
[0037] In step 310 , OF controller 150 performs topology discovery and creates a database of the data center network. In step 320 top of rack, aggregation, and backbone switches report traffic flow rates on each of their links to the OF controller. In step 330 OF controller 150 determines flow rates to specific links in the data center network. In step 340 forwarding entries are programmed in the form of one level multiple protocol label switching (MPLS) labels mapped to flow entries.
[0038] FIG. 4 shows a flow chart of a method 400 for load placement in a data center network, according to some embodiments. In some embodiments, method 400 may be performed by processor circuit 261 executing commands stored in memory circuit 262 in OF controller 250 . Furthermore, in some embodiments steps in method 400 may be partially performed by a processor circuit in some OF agents in the data center network, upon configuration by the OF controller. The data center network in method 400 may be as data center network 100 described in detail above (cf. FIG. 1 ).
[0039] In step 410 the OF controller programs a ‘push label’ operation in forwarding top of rack switches. The OF controller may perform step 410 by determining the flow rate to specific links in TOR layer 110 with ‘push label’ and flow entry programming operations. In step 420 , the OF controller programs ‘swap label’ operations in less loaded paths on switches in aggregation layer 120 . In step 430 the OF controller programs swap labels in less loaded paths on switches in backbone layer 130 . In step 440 the OF controller programs POP label operations on receiving switch in TOR layer 110 .
[0040] FIG. 5 shows a flow chart of a method 500 for load placement, according to some embodiments. In some embodiments, method 500 may be performed by processor circuit 261 executing commands stored in memory circuit 262 in OF controller 250 . Furthermore, in some embodiments some of the steps in method 500 may be partially performed by a processor circuit in some OF agents in the data center network, upon configuration by the OF controller. The data center network in method 500 may be similar to data center network 100 described in detail above (cf. FIG. 1 ).
[0041] In step 510 the OF controller receives notification of traffic flow through data center network 100 . In some embodiments, traffic flow information may be included in the appropriate N-tuple. In step 520 the OF controller allocates label space for each switch in the topology based on the switch's layer. When labels are pushed into switches in step 530 , label based forwarding is set to ‘ON’ in the switches in step 540 . Thus, the data packet may be forwarded to the address specified in the label. When step 550 determines an end flow status, the OF controller receives notification in step 560 . Also in step 560 , the OF controller releases the labels from the paths. In some embodiments, the flow information may be an aggregate entry such as a prefix rather than a complete IP address within a N-Tuple. This aggregate entry would indicate entire sub-networks or networks reachable at the far ends of the data center. Thus achieving a minimization of flow information space occupancy in the hardware tables of the switch.
[0042] FIG. 6 shows a flow chart of a method 600 for load placement in a data center network, according to some embodiments. In some embodiments, method 600 may be performed by processor circuit 261 executing commands stored in memory circuit 262 of OF controller 250 . Furthermore, in some embodiments some of the steps in method 600 may be partially performed by a processor circuit in some OF agents in the data center network, upon configuration by the OF controller. The data center network in method 600 may be as data center network 100 described in detail above (cf. FIG. 1 ).
[0043] In step 610 the OF controller maintains label space for each switch. In step 620 the OF controller constantly monitors traffic load through the data center network. Accordingly, in some embodiments step 620 includes monitoring traffic load through the data center network periodically. The periodicity in step 620 is not limiting and may vary from a few seconds up to minutes, or more. In some embodiments including a particularly large data center network, the OF controller may sequentially poll each of the nodes in step 620 . In step 630 the OF controller may select paths when traffic flow starts. In step 640 the OF controller releases paths when traffic flow ends.
[0044] FIG. 7 shows a data center network 700 configured for a node failure recovery, according to some embodiments. In some embodiments, the configuration of data center network 700 may be used under any circumstance where traffic re-routing may be desired. Data center network 700 may include a server layer 701 , according to some embodiments. Data center network 700 may include a TOR layer 710 , and aggregate layer 720 , and a backbone layer 730 . Thus, TOR layer 710 may include TOR switches 711 - 1 , 711 - 2 , 711 - 3 , and 711 - 4 . Aggregate layer 720 may include aggregate switches 721 - 1 , 721 - 2 , 721 - 3 , and 721 - 4 . And backbone layer 730 may include backbone switches 731 - 1 , 731 - 2 , 731 - 3 , and 731 - 4 . Data center network 700 may be configured for fail-re-routing (FRR) orchestration using bidirectional forwarding detection (BFD) between two nodes of the network.
[0045] Embodiments disclosed herein may include FRR providing a ‘make-before-break’ solution for protecting traffic flow in data center network 700 . Accordingly, in some embodiments when a node or link failure occurs in data center network 700 , the failure may be resolved without involving OF controller 150 . In some embodiments OF controller 150 calculates possible FRRs for each of the nodes and links in data center network 700 . The FRRs are stored by the OF agents associated with each node in the data center network, in memory circuit 272 (cf. FIG. 2 ). When a failure occurs at a particular point, traffic is rerouted according to the FRR associated with the point of failure. Thus, some embodiments reduce the round trip time for failure correction in the data center network by involving the OF agent installed locally on each of the nodes or switches in the network (cf. OF agent 275 in FIG. 2 ).
[0046] In some embodiments, the OF agent may install the FRR set for a particular TOR-Aggregation-Backbone combination of nodes in the hardware, and use the installed FRR set as backup paths for various scenarios. According to some embodiments, the OF agent may store the backup FRR set in memory. Thus, in the event of failure the FRR set is installed in the hardware (e.g., in the switches in data center network 700 ). OF controller 150 computes multiple FRR paths for each node or switch in data center network 700 . OF controller 150 is able to perform such computation by using detailed knowledge of the topology of data center network 700 .
[0047] According to some embodiments, each switch in data center network 700 is locally configured for BFD with respective adjacent layers. For example, switch 721 - 1 in aggregation layer 720 may be configured to perform BFD with a switch in backbone layer 730 (e.g., 731 - 1 or 731 - 2 ), and also with a switch in TOR layer 710 (e.g., 711 - 1 or 711 - 2 ). Likewise, in some embodiments switch 711 - 1 in TOR layer 710 may be configured to perform BFD with a switch in aggregation layer 720 . And switch 731 - 1 in backbone layer 730 may be configured to perform BFD sessions with a switch in aggregation layer 720 .
[0048] FIG. 7 shows an exemplary scenario wherein a failure is detected in backbone switch 731 - 3 . Thus, a data packet route from server 701 - 1 to server 701 - 2 through links 760 - 1 , 761 - 1 , 761 - 2 , 761 - 3 , 761 - 4 and 760 - 6 , is re-routed. The new route passes through links 760 - 1 , 760 - 2 , 760 - 3 , 760 - 4 , 760 - 5 , and 760 - 6 . In the example shown in FIG. 7 , a failure in backbone switch 731 - 3 involves a re-routing that begins in TOR switch 711 - 1 , changing from link 761 - 1 to link 760 - 2 . Thus, in the exemplary scenario a failure in the backbone layer produces a readjustment two layers ‘south,’ at the TOR level.
[0049] FIG. 8 shows data center network 700 configured for a link failure recovery, according to some embodiments. Data center 700 may be configured for FRR orchestration using bidirectional forwarding detection (BFD) between two nodes of the network, in case of a link failure.
[0050] FIG. 8 shows an exemplary scenario wherein a failure is detected in either one of link 861 - 1 or link 861 - 2 . Thus, a data packet route from server 701 - 1 to server 701 - 2 through links 860 - 1 , 860 - 2 , 861 - 1 , 861 - 2 , 860 - 5 , and 860 - 6 , is re-routed. The new route passes through links 860 - 1 , 860 - 2 , 860 - 3 , 860 - 4 , 860 - 5 , and 860 - 6 .
[0051] In some embodiments, OF controller 150 computes multiple FRR paths associated with each link in data center network 700 . For example, multiple FRR paths may be associated to link 861 - 1 such that each of the FRR paths is able to transfer a data packet from source server 701 - 1 to destination server 701 - 2 assuming a failure of link 861 - 1 . Thus, the path including links 860 - 1 , 860 - 2 , 860 - 3 , 860 - 4 , 860 - 5 , and 860 - 6 , and TOR switch 711 - 1 , aggregation switch 721 - 1 , backbone switch 731 - 3 , aggregation switch 721 - 3 , and TOR switch 711 - 3 may be included in an FRR set associated to either one of links 861 - 1 , and 861 - 2 . In some embodiments, OF controller 150 computes FRR paths for protection against a combination of a link failure and a node failure. In such embodiments, an FRR path set may be associated to both the link and the node whose failure is recovered. Further according to some embodiments, OF controller 150 may compute FRR paths in combination with user input, so that an administrator may select the type of protection path needed or desired for a data center network.
[0052] Accordingly, BFD sessions are performed between pairs of nodes, sending hand-shaking packets back and forth between the two nodes. When a BFD session between a pair of nodes reports a switch failure or a link failure, then the device which detects the failure reports the failure to the OF agent associated with the device. The OF agent in the device that detects the failure directs the flow to a backup path selected from the FRR set stored in memory.
[0053] In some embodiments, a user may select a recovery path from a group of FRR paths for a failed link and FRR paths for a failed switch, where the failed link and the failed switch may not be directly coupled to each other. In such scenario, OF controller 150 may configure the network to select the appropriate recovery path.
[0054] Some embodiments may implement a multi-hop BFD strategy, wherein the hand shaking packets are sent across multiple nodes and links in data center network 700 . For example, a multi-hop configuration may use a BFD session between two nodes in TOR layer 710 , so that the hand-shake packet transits across aggregation layer 720 and backbone layer 730 . In some embodiments, a BFD session may provide hand-shake packets between two nodes in aggregation layer 720 , across backbone layer 730 . More generally, some embodiments may implement multi-hop BFD sessions within a single layer and across multiple nodes, using an East-West links between switches (cf. FIG. 1 ).
[0055] In some embodiments, a single-hop BFD session coupling two adjacent nodes through a single link may take less than 50 milliseconds (ms) to complete. In the case of a multi-hop BFD session, latency times may be higher than 50 ms, but well below one (1) sec.
[0056] Thus, according to embodiments consistent with the present disclosure recovery through FRR paths may be implemented locally, through an OF agent associated to a switch, rather than being implemented at the OF controller level. This reduces the latency for implementation of the recovery protocol.
[0057] Embodiments of the disclosure described above are exemplary only. One skilled in the art may recognize various alternative embodiments from those specifically disclosed. Those alternative embodiments are also intended to be within the scope of this disclosure. As similar to such, the invention is limited only by the following claims. | A system for operating information handling systems forming a network including a plurality of switches is provided. The system includes an open flow controller coupled to each of the plurality of switches; a plurality of links, each link configured to transmit data packets between two switches from the plurality of switches; wherein: the open flow controller is configured to determine a traffic flow across each of the plurality of links; and each one of the plurality of switches is configured to re-route a data packet when the traffic flow in a link associated to the switch exceeds a threshold. A computer program product including a non-transitory computer readable medium having computer readable and executable code for instructing a processor in a management unit for a plurality of information handling systems as above is also provided. A network managing device coupled to a service provider having resources is also provided. | 7 |
[0001] The present application claims the priority to Chinese Patent Applications No. 201210360991.5, titled “VOLTAGE-CONTROLLED OSCILLATOR WITH LOW-NOISE AND LARGE TUNING RANGE”, No. 201210357276.6, titled “LOW-NOISE VOLTAGE-CONTROLLED OSCILLATOR”, No. 201210360745.X, titled “INTEGRATED LOW-NOISE VOLTAGE-CONTROLLED OSCILLATOR”, and No. 201210357240.8, titled “LOW-NOISE VOLTAGE-CONTROLLED OSCILLATOR”, filed with the Chinese State Intellectual Property Office on Sep. 21, 2012, which are incorporated herein by reference in their entireties.
FIELD
[0002] The present disclosure relates to the technical field of integrated circuit, and particularly to a low-noise voltage-controlled oscillator.
BACKGROUND
[0003] A voltage-controlled oscillator (VCO) refers to an oscillating circuit for which a correspondence relationship between an output frequency and an input control voltage exists.
[0004] The voltage-controlled oscillator is one of important basic circuits in the integrated circuit. The implementation of the voltage-controlled oscillator includes a ring voltage-controlled oscillator (Ring VCO) and an inductance-capacitance voltage-controlled oscillator (LC VCO). The voltage-controlled oscillator is widely applied to a clock synchronization circuit in a microprocessor, a frequency synthesizer in a wireless communication transceiver, a multi-phase sampling circuit and a clock recovery circuit (CRC) in optical-fiber communication.
[0005] Phase noise is one of main parameters for measuring performance of the voltage-controlled oscillator. In most cases, the phase noise performance of the voltage-controlled oscillator is the dominating factor for sensitivity of an integrated receiver. Ideally, a signal spectrum output by a voltage-controlled oscillator is an impulse function. However, signal spectrum characteristics output by the voltage-controlled oscillator is a frequency response masking curve since various noise sources exist in practical circuit.
[0006] The noise source in the voltage-controlled oscillator circuit may include a device noise and an external interference noise. The device noise mainly includes a thermal noise and a flicker noise, and the external interference noise mainly includes a substrate noise and a power supply noise. The device noise in the voltage-controlled oscillator mainly comes from a parasitic series resistance of an on-chip inductor and a variable capacitor, a switch differential pair tube and a tail current source.
SUMMARY
[0007] The technical problem to be solved in the present disclosure is to provide a low-noise voltage-controlled oscillator having large output voltage amplitude, thus phase noise in the whole circuit can be reduced and phase noise performance can be improved.
[0008] A low-noise voltage-controlled oscillator is provided in the present disclosure. The low-noise voltage-controlled oscillator includes a resonance circuit, a negative resistance circuit, a current source circuit and a feedback circuit,
[0009] the resonance circuit is configured to generate an oscillation signal of the voltage-controlled oscillator, the resonance circuit is an inductance-capacitance resonance circuit, and a capacitor in the resonance circuit is formed by a MOS varactor or a backward diode;
[0010] the negative resistance circuit is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit;
[0011] the current source circuit is configured to generate a current for operation of the voltage-controlled oscillator; and
[0012] the feedback circuit is configured to feed back the oscillation signal generated by the resonance circuit to the current source circuit.
[0013] Preferably, a master device for providing a current in the current source circuit is a MOS transistor or a triode.
[0014] In a case that the master device for providing a current in the current source circuit is the MOS transistor, the current source circuit includes a first MOS transistor, a second MOS transistor, a fifth resistor, a sixth resistor, a ninth capacitor and a tenth capacitor.
[0015] A gate of the first MOS transistor is connected to the ninth capacitor that is grounded and the gate of the first MOS transistor is an input terminal for a first feedback signal of the feedback circuit, and a source of the first MOS transistor is grounded.
[0016] A gate of the second MOS transistor is connected to the tenth capacitor that is grounded and the gate of the second MOS transistor is an input terminal for a second feedback signal of the feedback circuit, and a source of the second MOS transistor is grounded.
[0017] A drain of the first MOS transistor is connected to a drain of the second MOS transistor, and a connection node between the drain of the first MOS transistor and the drain of the second MOS transistor is a connection node between an input terminal of the negative resistance circuit and an output terminal of the current source circuit.
[0018] One end of the fifth resistor is connected to the gate of the first MOS transistor, and the other end of the fifth resistor is connected to a third control voltage.
[0019] One end of the sixth resistor is connected to the gate of the second MOS transistor, and the other end of the sixth resistor is connected to the third control voltage.
[0020] In a case that the master device for providing a current in the current source circuit is the triode, the current source circuit includes a third bipolar transistor, a fourth bipolar transistor, a fifth resistor, a sixth resistor, a ninth capacitor and a tenth capacitor.
[0021] A base of the third bipolar transistor is connected to the ninth capacitor that is grounded and the base of the third bipolar transistor is an input terminal for a first feedback signal, and an emitter of the third bipolar transistor is grounded.
[0022] A base of the fourth bipolar transistor is connected to the tenth capacitor that is grounded and the base of the fourth bipolar transistor is an input terminal for a second feedback signal, and an emitter of the fourth bipolar transistor is grounded.
[0023] A collector of the third bipolar transistor is connected to a collector of the fourth bipolar transistor, and a connection node between the collector of the third bipolar transistor and the collector of the fourth bipolar transistor is a connection node between an input terminal of the negative resistance circuit and an output terminal of the current source circuit.
[0024] One end of the fifth resistor is connected to the base of the third bipolar transistor, and the other end of the fifth resistor is connected to a third control voltage.
[0025] One end of the sixth resistor is connected to the base of the fourth bipolar transistor, and the other end of the sixth resistor is connected to the third control voltage.
[0026] Preferably, in a case that the capacitor in the resonance circuit is formed by the MOS varactor,
[0027] the resonance circuit includes a differential inductor, a first MOS varactor, a second MOS varactor, a third capacitor, a fourth capacitor, a first resistor and a second resistor.
[0028] One end of the differential inductor is connected to a first node, and the other end of the differential inductor is connected to a second node.
[0029] A gate of the first MOS varactor is connected to a third node, and a drain and a source of the first MOS varactor are shorted together and connected to a first control voltage.
[0030] A gate of the second MOS varactor is connected to a fourth node, and a drain and a source of the second MOS varactor are shorted together and connected to the first control voltage.
[0031] One end of the first resistor is connected to the third node, and the other end of the first resistor is grounded.
[0032] One end of the second resistor is connected to the fourth node, and the other end of the second resistor is grounded.
[0033] Two ends of the third capacitor are respectively connected to the first node and the third node, and two ends of the fourth capacitor are respectively connected to the second node and the fourth node.
[0034] The first node is a first connection node between the resonance circuit and the negative resistance circuit and outputs a first resonant signal, and the second node is a second connection node between the resonance circuit and the negative resistance circuit and outputs a second resonant signal.
[0035] In a case that the capacitor in the resonance circuit is formed by the backward diode,
[0036] the resonance circuit includes a differential inductor, a first backward diode, a second backward diode, a third capacitor, a fourth capacitor, a first resistor and a second resistor.
[0037] One end of the differential inductor is connected to a first node, and the other end of the differential inductor is connected to a second node.
[0038] An anode of the first backward diode is connected to a third node, and a cathode of the first backward diode is connected to a first control voltage.
[0039] An anode of the second backward diode is connected to a fourth node, and a cathode of the second backward diode is connected to the first control voltage.
[0040] One end of the first resistor is connected to the third node, and the other end of the first resistor is grounded.
[0041] One end of the second resistor is connected to the fourth node, and the other end of the second resistor is grounded.
[0042] Two ends of the third capacitor are respectively connected to the first node and the third node, and two ends of the fourth capacitor are respectively connected to the second node and the fourth node.
[0043] The first node is a first connection node between the resonance circuit and the negative resistance circuit and outputs a first resonant signal, and the second node is a second connection node between the resonance circuit and the negative resistance circuit and outputs a second resonant signal.
[0044] Preferably, the negative resistance circuit includes a first bipolar transistor, a second bipolar transistor, a third resistor, a fourth resistor, a fifth capacitor, a sixth capacitor and an eleventh capacitor.
[0045] A base of the first bipolar transistor is connected to a fifth node, and a collector of the first bipolar transistor is connected to a first node which is a first connection node between the negative resistance circuit and the resonance circuit.
[0046] A base of the second bipolar transistor is connected to a sixth node, and a collector of the second bipolar transistor is connected to a second node which is a second connection node between the negative resistance circuit and the resonance circuit.
[0047] An emitter of the first bipolar transistor is connected to an emitter of the second bipolar transistor, and a connection node between the emitter of the first bipolar transistor and the emitter of the second bipolar transistor is a connection node between an input terminal of the negative resistance circuit and an output terminal of the current source circuit.
[0048] One end of the third resistor is connected to the fifth node, and the other end of the third resistor is connected to a second control voltage.
[0049] One end of the fourth resistor is connected to the sixth node, and the other end of the fourth resistor is connected to the second control voltage.
[0050] One end of the fifth capacitor is connected to the first node, and the other end of the fifth capacitor is connected to the sixth node.
[0051] One end of the sixth capacitor is connected to the second node, and the other end of the sixth capacitor is connected to the fifth node.
[0052] Two ends of the eleventh capacitor are respectively connected to the second control voltage and ground.
[0053] Preferably,
[0054] the feedback circuit includes a seventh capacitor and an eighth capacitor.
[0055] One end of the seventh capacitor is connected to a first output terminal of the resonance circuit, the other end of the seventh capacitor is connected to a first signal input terminal of the current source circuit, a first resonant signal is fed back to the current source circuit via the seventh capacitor, and the other end of the seventh capacitor is a first output terminal of the voltage-controlled oscillator.
[0056] One end of the eighth capacitor is connected to a second output terminal of the resonance circuit, the other end of the eighth capacitor is connected to a second signal input terminal of the current source circuit, a second resonant signal is fed back to the current source circuit via the eighth capacitor, and the other end of the eighth capacitor is a second output terminal of the voltage-controlled oscillator.
[0057] Preferably, capacitances of the third capacitor and the fourth capacitor are at least 10 times greater than capacitances of the first MOS varactor and the second MOS varactor.
[0058] Preferably, the first MOS varactor and the second MOS varactor operate in an accumulation region or a depletion region.
[0059] Preferably, the first bipolar transistor and the second bipolar transistor are in a forward operating region.
[0060] Preferably, the third bipolar transistor and the fourth bipolar transistor are in a forward operating region.
[0061] Preferably, the first backward diode and the second backward diode operate in a reverse operating region.
[0062] Preferably, the first MOS transistor and the second MOS transistor are in a saturation region.
[0063] Compared with the conventional technology, the present disclosure has the following advantages.
[0064] In the voltage-controlled oscillator with low-noise and large tuning range according to the present disclosure, the current source circuit is configured to generate a current for operation of the voltage-controlled oscillator; the resonance circuit is configured to generate an oscillation signal of the voltage-controlled oscillator; the resonance circuit is an inductance-capacitance resonance circuit, a capacitor in the resonance circuit is formed by a MOS varactor to increase the tuning range of the circuit; the negative resistance circuit is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit; and the feedback circuit is configured to feed back the oscillation signal generated by the resonance circuit to the current source circuit to inject a new current for the current source so as to improve the use efficiency of the voltage-controlled oscillator. Therefore, the voltage-controlled oscillator according to the embodiments of the present disclosure has larger output voltage amplitude. The phase noise performance of the voltage-controlled oscillator is better as the output voltage amplitude of the voltage-controlled oscillator is larger.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1 is a schematic view of a voltage-controlled oscillator in the conventional technology;
[0066] FIG. 2 is a schematic view of a low-noise voltage-controlled oscillator according to a first embodiment of the present disclosure;
[0067] FIG. 3 is a schematic view of a low-noise voltage-controlled oscillator according to a second embodiment of the present disclosure;
[0068] FIG. 4 is a schematic view of a low-noise voltage-controlled oscillator according to a third embodiment of the present disclosure;
[0069] FIG. 5 is a schematic view of a low-noise voltage-controlled oscillator according to a fourth embodiment of the present disclosure;
[0070] FIG. 6 is a schematic view of a low-noise voltage-controlled oscillator according to a fifth embodiment of the present disclosure;
[0071] FIG. 7 is a circuit diagram of a low-noise voltage-controlled oscillator according to a sixth embodiment of the present disclosure;
[0072] FIG. 8 is a circuit diagram of a low-noise voltage-controlled oscillator according to a seventh embodiment of the present disclosure; and
[0073] FIG. 9 is a circuit diagram of a low-noise voltage-controlled oscillator according to an eighth embodiment of the present disclosure.
DETAILED DESCRIPTION
[0074] In order to make the above objectives, features and advantages of the present disclosure more apparent, embodiments of the present disclosure will be explained in detail below in conjunction with the accompanying drawings.
[0075] Reference is made to FIG. 2 which is a schematic view of a low-noise voltage-controlled oscillator according to a first embodiment of the present disclosure.
[0076] The low-noise voltage-controlled oscillator according to the present embodiment includes a resonance circuit 100 , a negative resistance circuit 200 , a current source circuit 300 and a feedback circuit 400 .
[0077] The resonance circuit 100 is configured to generate an oscillation signal of the voltage-controlled oscillator. The resonance circuit 100 is an inductance-capacitance resonance circuit, and a capacitor in the resonance circuit 100 is formed by a MOS varactor.
[0078] The negative resistance circuit 200 is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit 100 .
[0079] The current source circuit 300 is configured to generate a current for operation of the voltage-controlled oscillator.
[0080] The feedback circuit 400 is configured to feed back the oscillation signal generated by the resonance circuit 100 to the current source circuit 300 .
[0081] In the low-noise voltage-controlled oscillator according to the present disclosure, the current source circuit 300 is configured to generate a current for operation of the voltage-controlled oscillator; the resonance circuit 100 is configured to generate an oscillation signal of the voltage-controlled oscillator; the resonance circuit 100 is an inductance-capacitance resonance circuit, the capacitor in the resonance circuit 100 is formed by a MOS varactor to increase the tuning range of the circuit; the negative resistance circuit 200 is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit 100 ; and the feedback circuit 400 is configured to feed back the oscillation signal generated by the resonance circuit 100 to the current source circuit 300 to inject a new current for the current source circuit 300 so as to improve the use efficiency of the voltage-controlled oscillator. Therefore, the voltage-controlled oscillator according to the embodiment of the present disclosure has larger output voltage amplitude. The phase noise performance of the voltage-controlled oscillator is better as the output voltage amplitude of the voltage-controlled oscillator is larger.
[0082] The capacitor in the resonance circuit 100 in the embodiment as shown in FIG. 2 is formed by a MOS varactor. An embodiment in which the capacitor in the resonance circuit is formed by a backward diode is described as follows.
[0083] Reference is made to FIG. 3 which is a schematic view of a low-noise voltage-controlled oscillator according to a second embodiment of the present disclosure.
[0084] The low-noise voltage-controlled oscillator according to the present embodiment includes a resonance circuit 100 , a negative resistance circuit 200 , a current source circuit 300 and a feedback circuit 400 .
[0085] The resonance circuit 100 is configured to generate an oscillation signal of the voltage-controlled oscillator. The resonance circuit 100 is an inductance-capacitance resonance circuit, and the capacitor in the resonance circuit is formed by a backward diode.
[0086] The negative resistance circuit 200 is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit 100 .
[0087] The current source circuit 300 is configured to generate a current for operation of the voltage-controlled oscillator.
[0088] The feedback circuit 400 is configured to feed back the oscillation signal generated by the resonance circuit 100 to the current source circuit 300 .
[0089] In the low-noise voltage-controlled oscillator according to the present disclosure, the current source circuit 300 is configured to generate a current for operation of the voltage-controlled oscillator; the resonance circuit 100 is configured to generate an oscillation signal of the voltage-controlled oscillator; the resonance circuit 100 is an inductance-capacitance resonance circuit, the capacitor in the resonance circuit is formed by a backward diode; the negative resistance circuit 200 is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit 100 ; and the feedback circuit 400 is configured to feed back the oscillation signal generated by the resonance circuit 100 to the current source circuit 300 to inject a new current for the current source circuit 300 so as to improve the use efficiency of the voltage-controlled oscillator. Therefore, the voltage-controlled oscillator according to the embodiment of the present disclosure has larger output voltage amplitude. The phase noise performance of the voltage-controlled oscillator is better as the output voltage amplitude of the voltage-controlled oscillator is larger.
[0090] The two implementations of the resonance circuit are described in the above embodiments. Two implementations of the current source circuit are described in detail in conjunction with accompanying drawings in the following.
[0091] Reference is made to FIG. 4 which is a schematic view of a low-noise voltage-controlled oscillator according to a third embodiment of the present disclosure.
[0092] The low-noise voltage-controlled oscillator according to the embodiment of the present disclosure includes a resonance circuit 100 , a negative resistance circuit 200 , a current source circuit 300 and a feedback circuit 400 .
[0093] The resonance circuit 100 is configured to generate an oscillation signal of the voltage-controlled oscillator. The resonance circuit 100 is an inductance-capacitance resonance circuit, and the capacitor in the resonance circuit is formed by a backward diode.
[0094] The negative resistance circuit 200 is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit 100 .
[0095] The feedback circuit 400 is configured to feed back the oscillation signal generated by the resonance circuit 100 to the current source circuit 300 .
[0096] The current source circuit 300 is configured to generate a current for operation of the voltage-controlled oscillator. The current source circuit 300 includes a first MOS transistor M 1 , a second MOS transistor M 2 , a fifth resistor R 5 , a sixth resistor R 6 , a ninth capacitor C 9 and a tenth capacitor C 10 .
[0097] A gate of the first MOS transistor M 1 is connected to the ninth capacitor C 9 that is grounded and the gate of the first MOS transistor M 1 is an input terminal for a first feedback signal of the feedback circuit 400 , and a source of the first MOS transistor M 1 is grounded.
[0098] A gate of the second MOS transistor M 2 is connected to the tenth capacitor C 10 that is grounded and the gate of the second MOS transistor M 2 is an input terminal for a second feedback signal of the feedback circuit 400 , and a source of the second MOS transistor M 2 is grounded.
[0099] A drain of the first MOS transistor M 1 is connected to a drain of the second MOS transistor M 2 , and a connection node between the drain of the first MOS transistor M 1 and the drain of the second MOS transistor M 2 is a connection node between an input terminal of the negative resistance circuit 200 and an output terminal of the current source circuit 300 .
[0100] One end of the fifth resistor R 5 is connected to the gate of the first MOS transistor M 1 , and the other end of the fifth resistor R 5 is connected to a third control voltage VBIAS.
[0101] One end of the sixth resistor R 6 is connected to the gate of the second MOS transistor M 2 , and the other end of the sixth resistor R 6 is connected to the third control voltage VBIAS.
[0102] It should be noted that M 1 and M 2 may be in a saturation region by controlling the voltage value of the third control voltage VBIAS.
[0103] It should be noted that C 9 and C 10 can be used for filtering, and filtering out high frequency signals generated by Q 3 and Q 4 .
[0104] In the low-noise voltage-controlled oscillator according to the present disclosure, the current source circuit 300 is configured to generate a current for operation of the voltage-controlled oscillator; the resonance circuit 100 is configured to generate an oscillation signal of the voltage-controlled oscillator; the resonance circuit 100 is an inductance-capacitance resonance circuit, the capacitor in the resonance circuit is formed by a backward diode; the negative resistance circuit 200 is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit 100 ; and the feedback circuit 400 is configured to feed back the oscillation signal generated by the resonance circuit 100 to the current source circuit 300 to inject a new current for the current source circuit 300 so as to improve the use efficiency of the voltage-controlled oscillator. In addition, the first MOS transistor and the second MOS transistor are adopted for the current source current, and the voltage-controlled oscillator according to the embodiment of the present disclosure has larger output voltage amplitude since the first MOS transistor and the second MOS transistor have small threshold voltage. The phase noise performance of the voltage-controlled oscillator is better as the output voltage amplitude of the voltage-controlled oscillator is larger.
[0105] Reference is made to FIG. 5 which is a schematic view of a low-noise voltage-controlled oscillator according to a fourth embodiment of the present disclosure.
[0106] FIG. 5 differs from FIG. 4 in that the capacitor in the resonance circuit 100 is formed by a MOS varactor.
[0107] In the low-noise voltage-controlled oscillator according to the present disclosure, the current source circuit 300 is configured to generate a current for operation of the voltage-controlled oscillator; the resonance circuit 100 is configured to generate an oscillation signal of the voltage-controlled oscillator; the resonance circuit 100 is an inductance-capacitance resonance circuit, the capacitor in the resonance circuit 100 is formed by a MOS varactor to increase the tuning range of the circuit; the negative resistance circuit 200 is configured to generate a negative resistance to counteract a positive resistance generated by the resonance circuit 100 ; and the feedback circuit 400 is configured to feed back the oscillation signal generated by the resonance circuit 100 to the current source circuit 300 to inject a new current for the current source circuit 300 so as to improve the use efficiency of the voltage-controlled oscillator. In addition, the first MOS transistor and the second MOS transistor are adopted for the current source current, and the voltage-controlled oscillator according to the embodiment of the present disclosure has larger output voltage amplitude since the first MOS transistor and the second MOS transistor have small threshold voltage. The phase noise performance of the voltage-controlled oscillator is better as the output voltage amplitude of the voltage-controlled oscillator is larger.
[0108] A specific structure of the voltage-controlled oscillator according to the embodiment of the present disclosure is described in conjunction with accompanying drawings in the following.
[0109] Reference is made to FIG. 6 which is a schematic view of a low-noise voltage-controlled oscillator according to a fifth embodiment of the present disclosure.
[0110] The voltage-controlled oscillator according to the embodiment of the present disclosure includes a resonance circuit, a negative resistance circuit, a current source circuit and a feedback circuit.
[0111] The resonance circuit includes a differential inductor L 0 , a first MOS varactor C 1 , a second MOS varactor C 2 , a third capacitor C 3 , a fourth capacitor C 4 , a first resistor R 1 and a second resistor R 2 .
[0112] A tap of the differential inductor L 0 is connected to a power source.
[0113] One end of the differential inductor L 0 is connected to a first node A, and the other end of the differential inductor L 0 is connected to a second node B.
[0114] A gate of the first MOS varactor is connected to a third node C, and a drain and a source of the first MOS varactor are shorted together and connected to a first control voltage ATUNE.
[0115] A gate of the second MOS varactor is connected to a fourth node D, and a drain and a source of the second MOS varactor are shorted together and connected to the first control voltage ATUNE.
[0116] The operating frequency of the voltage-controlled oscillator may be adjusted by adjusting the value of the first control voltage ATUNE.
[0117] One end of the first resistor R 1 is connected to the third node C, and the other end of the first resistor R 1 is grounded.
[0118] One end of the second resistor R 2 is connected to the fourth node D, and the other end of the second resistor R 2 is grounded.
[0119] Two ends of the third capacitor C 3 are respectively connected to the first node A and the third node C, and two ends of the fourth capacitor C 4 are respectively connected to the second node B and the fourth node D.
[0120] The first node A is a first connection node between the resonance circuit and the negative resistance circuit and outputs a first resonant signal. The second node B is a second connection node between the resonance circuit and the negative resistance circuit and outputs a second resonant signal.
[0121] It should be noted that C 1 and C 2 operate in an accumulation region or a depletion region.
[0122] Capacitances of the third capacitor C 3 and the fourth capacitor C 4 are at least 10 times greater than capacitances of the first MOS varactor Cl and the second MOS varactor C 2 . In this way, a wide frequency tuning range of the voltage-controlled oscillator according to the embodiment of the present disclosure can be ensured.
[0123] It should be noted that the capacitor in the resonance circuit according to the embodiment of the present disclosure is formed by MOS varactors (C 1 and C 2 ). The capacitance value of the MOS varactor significantly varies with the first control voltage ATUNE, and thus the voltage-controlled oscillator adopting the MOS varactor has a wide tuning range.
[0124] The negative resistance circuit includes a first transistor bipolar transistor Q 1 , a second bipolar transistor Q 2 , a third resistor R 3 , a fourth resistor R 4 , a fifth capacitor C 5 , a sixth capacitor C 6 and an eleventh capacitor C 11 .
[0125] A base of the first bipolar transistor Q 1 is connected to a fifth node M, and a collector of the first bipolar transistor Q 1 is connected to the first node A which is a first connection node between the negative resistance circuit and the resonance circuit.
[0126] A base of the second bipolar transistor Q 2 is connected to a sixth node N, and a collector of the second bipolar transistor Q 2 is connected to the second node B which is a second connection node between the negative resistance circuit and the resonance circuit.
[0127] An emitter of the first bipolar transistor Q 1 is connected to an emitter of the second bipolar transistor Q 2 , and a connection node between the emitter of the first bipolar transistor Q 1 and the emitter of the second bipolar transistor Q 2 is a connection node between an input terminal of the negative resistance circuit and an output terminal of the current source circuit.
[0128] One end of the third resistor R 3 is connected to the fifth node M, and the other end of the third resistor R 3 is connected to a second control voltage CDC.
[0129] One end of the fourth resistor R 4 is connected to the sixth node N, and the other end of the fourth resistor R 4 is connected to the second control voltage CDC.
[0130] One end of the fifth capacitor C 5 is connected to the first node A, and the other end of the fifth capacitor C 5 is connected to the sixth node N.
[0131] One end of the sixth capacitor C 6 is connected to the second node B, and the other end of the sixth capacitor C 6 is connected to the fifth node M.
[0132] The fifth capacitor C 5 and the sixth capacitor C 6 are mainly used for isolating a direct current signal and assisting Q 1 and Q 2 to implement a negative resistance so as to counteract a positive resistance generated by the resonance circuit.
[0133] Two ends of the eleventh capacitor C 11 are respectively connected to the second control voltage CDC and ground.
[0134] It should be noted that Q 1 and Q 2 may be ensured to be in a forward operating region by adjusting the value of the second control voltage CDC.
[0135] The current source circuit includes a third bipolar transistor Q 3 , a fourth bipolar transistor Q 4 , a fifth resistor R 5 , a sixth resistor R 6 , a ninth capacitor C 9 and a tenth capacitor C 10 .
[0136] A base of the third bipolar transistor Q 3 is connected to the ninth capacitor C 9 that is grounded and the base of the third bipolar transistor Q 3 is an input terminal for a first feedback signal, and an emitter of the third bipolar transistor Q 3 is grounded.
[0137] A base of the fourth bipolar transistor Q 4 is connected to the tenth capacitor C 10 that is grounded and the base of the fourth bipolar transistor Q 4 is an input terminal for a second feedback signal, and an emitter of the fourth bipolar transistor Q 4 is grounded.
[0138] A collector of the third bipolar transistor Q 3 is connected to a collector of the fourth bipolar transistor Q 4 , and a connection node between the collector of the third bipolar transistor Q 3 and the collector of the fourth bipolar transistor Q 4 is a connection node between an input terminal of the negative resistance circuit and an output terminal of the current source circuit.
[0139] One end of the fifth resistor R 5 is connected to the base of the third bipolar transistor Q 3 , and the other end of the fifth resistor R 5 is connected to a third control voltage VBIAS.
[0140] One end of the sixth resistor R 6 is connected to the base of the fourth bipolar transistor Q 4 , and the other end of the sixth resistor R 6 is connected to the third control voltage VBIAS.
[0141] It should be noted that Q 3 and Q 4 may be in the forward operating region by adjusting the voltage value of VBIAS.
[0142] It should be noted that C 9 and C 10 are used for filtering, and filtering out high frequency signals generated by Q 3 and Q 4 .
[0143] It should be noted that Q 1 , Q 2 , Q 3 and Q 4 may be HBT.
[0144] The feedback circuit includes a seventh capacitor C 7 and an eighth capacitor C 8 .
[0145] One end of the seventh capacitor C 7 is connected to a first output terminal (the first node A) of the resonance circuit, the other end of the seventh capacitor C 7 is connected to a first signal input terminal of the current source circuit, a first resonant signal is fed back to the current source circuit via the seventh capacitor C 7 , and the other end of the seventh capacitor C 7 is a first output terminal NOUT of the voltage-controlled oscillator.
[0146] One end of the eighth capacitor C 8 is connected to a second output terminal (the second node B) of the resonance circuit, the other end of the eighth capacitor C 8 is connected to a second signal input terminal of the current source circuit, a second resonant signal is fed back to the current source circuit via the eighth capacitor C 8 , and the other end of the eighth capacitor C 8 is a second output terminal POUT of the voltage-controlled oscillator.
[0147] The seventh capacitor C 7 and the eighth capacitor C 8 are mainly used for isolating a direct current and feeding back an alternating current signal to the current source circuit to inject a new current for the current source circuit. Therefore, the oscillation signal generated by the resonance circuit is fed back and used, and thus the use efficiency is improved.
[0148] It should be noted that POUT and NOUT are two output terminals of the voltage-controlled oscillator. The oscillation signals output by the two output terminals are both positive voltage signals, but the oscillation signals output by POUT and NOUT have opposite phases.
[0149] Capacitances of the seventh capacitor C 7 and the eighth capacitor C 8 are one tenth of capacitances of the first MOS varactor C 1 and the second MOS varactor C 2 , and thus it is ensured that the voltage-controlled oscillator has a wide frequency tuning range.
[0150] The operational principle of the voltage-controlled oscillator according to the present disclosure is explained in detail below in conjunction with FIG. 2 .
[0151] The phase noise of the voltage-controlled oscillator may be represented as:
[0000]
L
{
Δ
ω
}
=
10
·
log
[
kT
·
R
eff
(
1
+
F
)
(
ω
0
Δ
ω
)
2
V
max
2
/
2
]
(
1
)
[0152] where F is an empirical coefficient; k is the boltzmann constant; T is an absolute temperature; Δω is an offset frequency relative to a carrier frequency ω 0 ; V max is a voltage amplitude of the resonance circuit; and R eff is an effective resistance. It should be noted that the smaller the phase noise is, the better the phase noise performance of the voltage-controlled oscillator is.
[0153] The current source circuit is configured to generate a current for operation of the voltage-controlled oscillator.
[0154] The resonance circuit and the negative resistance circuit are configured to generate an oscillation signal.
[0155] The oscillation signal generated by the resonance circuit and the negative resistance resistance is fed back to the bases of the HBTs (Q 3 and Q 4 ) in the current source circuit via the capacitors (C 7 and C 8 ) in the feedback circuit. Under the same direct current bias condition, the current source circuit of the voltage-controlled oscillator according to the embodiment of the present disclosure has a smaller voltage drop compared with the current source circuit of the voltage-controlled oscillator in the conventional technology, and thus the voltage-controlled oscillator according to the embodiment of the present disclosure has a larger output voltage amplitude.
[0156] It can be known from formula (1) that the larger the output voltage amplitude of the voltage-controlled oscillator is, the better the phase noise performance of the voltage-controlled oscillator is.
[0157] The output voltages (direct voltages of POUT and NOUT) of the voltage-controlled oscillator according to the embodiment of the present disclosure the voltage drop of base-emitter of Q 3 or Q 4 , therefore, a peak-to-peak voltage output by the voltage-controlled oscillator is increased and the phase noise performance of the voltage-controlled oscillator is improved.
[0158] The voltage-controlled oscillator enables base voltages of the HBTs (Q 1 and Q 4 ) to have similar phases by the feedback circuit and thus enables the current of the voltage-controlled oscillator to reach a minimum value in its noise sensitive area, and therefore the phase noise performance of the voltage-controlled oscillator is improved.
[0159] A voltage-controlled oscillator is further provided according to the present disclosure. Reference is made to FIG. 7 which is a circuit diagram of a low-noise voltage-controlled oscillator according to a sixth embodiment of the present disclosure.
[0160] FIG. 7 differs from FIG. 6 in that the capacitor in the resonance circuit is formed by a backward diode.
[0161] The resonance circuit includes a differential inductor L 0 , a first backward diode C 1 , a second backward diode C 2 , a third capacitor C 3 , a fourth capacitor C 4 , a first resistor R 1 and a second resistor R 2 .
[0162] A tap of the differential inductor L 0 is connected to a power source.
[0163] One end of the differential inductor L 0 is connected to a first node A, and the other end of the differential inductor L 0 is connected to a second node B.
[0164] An anode of the first backward diode C 1 is connected to a third node C, and a cathode of the first backward diode C 1 is connected to a first control voltage ATUNE.
[0165] An anode of the second backward diode C 2 is connected to a fourth node D, and a cathode of the second backward diode is connected to the first control voltage ATUNE. The operating frequency of the voltage-controlled oscillator may be adjusted by adjusting the value of the first control voltage ATUNE.
[0166] One end of the first resistor R 1 is connected to the third node C, and the other end of the first resistor R 1 is grounded.
[0167] One end of the second resistor R 2 is connected to the fourth node D, and the other end of the second resistor R 2 is grounded.
[0168] Two ends of the third capacitor C 3 are respectively connected to the first node A and the third node C, and two ends of the fourth capacitor C 4 are respectively connected to the second node B and the fourth node D.
[0169] The first node A is a first connection node between the resonance circuit and the negative resistance circuit and outputs a first resonant signal. The second node B is a second connection node between the resonance circuit and the negative resistance circuit and outputs a second resonant signal.
[0170] It should be noted that C 1 and C 2 operate in a reverse operating region.
[0171] Capacitances of the third capacitor C 3 and the fourth capacitor C 4 are at least 10 times greater than capacitances of the first backward diode C 1 and the second backward diode C 2 . Thus it may be ensured that the voltage-controlled oscillator according to the embodiment of the present disclosure has a wide frequency tuning range.
[0172] It should be noted that the capacitor in the resonance circuit according to the embodiment of the present disclosure is formed by backward diodes (C 1 and C 2 ). Since the backward diode operates in the reverse operating region, the capacitance of the backward diode little varies with the first control voltage ATUNE compared with the MOS varactor. Therefore, the voltage-controlled oscillator adopting the backward diode has a smaller gain and thus has a better phase noise.
[0173] A voltage-controlled oscillator is further provided according to the present disclosure. Reference is made to FIG. 8 which is a circuit diagram of a low-noise voltage-controlled oscillator according to a seventh embodiment of the present disclosure.
[0174] The current source in FIG. 8 is the same as the current sources in FIG. 4 and FIG. 5 , and other modules except the current source circuit in FIG. 8 are the same as those in FIG. 7 , which is not repeated herein.
[0175] A voltage-controlled oscillator is further provided according to the present disclosure. Reference is made to FIG. 9 which is a circuit diagram of a low-noise voltage-controlled oscillator according to an eighth embodiment of the present disclosure.
[0176] The current source in FIG. 9 is the same as the current sources in FIG. 4 and FIG. 5 , and other modules except the current source circuit in FIG. 9 are the same as those in FIG. 6 , which is not repeated herein.
[0177] The embodiments as above described are merely preferred embodiments of the present disclosure, which are not to limit the present disclosure in any form. The preferred embodiments of the present disclosure are disclosed above, which should not be interpreted as limiting the present disclosure. Numerous possible alternations, modifications and equivalents can be made to the technical solution of the present disclosure by those skilled in the art in light of the methods and technical content disclosed herein without deviation from the scope of technical solutions of the present disclosure. Therefore, any simple alternations, modifications and equivalents made to the embodiments above according to the technical essential of the present disclosure without deviation from the content of technical solutions of the present disclosure should fall within the scope of protection of technical solutions of the present disclosure. | A low-noise and big tuning range voltage-controlled oscillator. Wherein a current source circuit is used for generating working current of the voltage-controlled oscillator, a resonance circuit is used for generating an oscillating signal of the voltage-controlled oscillator, the resonance circuit is an inductance and capacitance type resonance circuit, wherein capacitance adopts a metal oxide semiconductor (MOS) capacitive reactance tube or a reverse diode to increase the tuning range of the circuit, a negative resistance circuit is used for generating negative resistance to counteract positive resistance generated by the resonance circuit, and a feedback circuit is used for feeding back the oscillating signal generated by the resonance circuit to the current source circuit to add a new current to the current source so as to improve the use efficiency of the voltage controlled oscillator. Therefore, the voltage controlled oscillator has larger output voltage amplitude. Tho larger the output voltage amplitude of the voltage controlled oscillator is, the better the phase noise performance is. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application No. 62/158,609, filed May 8, 2015, entitled “DEBUNKING RUMORS IN TWITTER BEFORE NEWS ORGANIZATIONS” and U.S. Provisional Application No. 62/186,419, filed Jun. 30, 2015, entitled “SYSTEM AND METHOD FOR AUTOMATICALLY DETECTING AND VERIFYING SOCIAL MEDIA EVENTS”. Each of the applications referred to in this paragraph is incorporated herein by reference in its entirety.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material, which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever. The following notice applies to this document: Copyright @ 2015 Thomson Reuters.
TECHNICAL FIELD
[0003] This disclosure relates to event detection and verification, and more particularly methods and systems for detecting and verifying an event from social media data.
BACKGROUND
[0004] Social media platforms like Twitter® or Facebook®, have influenced news gathering. Every minute, people around the world are posting pictures, videos, tweeting and otherwise communicating about all sorts of events and happenings. For example, a person may comment on what they see at a scene of an accident in real-time. Since people geographically close to an event are a valuable source of breaking news, the information generated by them is potentially very valuable. However, leveraging such information is very difficult.
[0005] According to statistics on the Twitter® website, there are approximately 320 million twitter users, of which, 65 million are in the United States and 254 million internationally (Twitter Q4 2015 Earnings Report, pp. 4). There are also approximately 350,000 tweets per minute. The percentage of valuable information is very small compared to the entire social media data available at a time. It has been noted that social media data primarily includes rumors, noise, spam, and mostly information useless to a professional consumer. As a result, potentially useful information is very hard to discover. Furthermore, discovery of useful information does not assure accuracy of the claimed event.
[0006] Currently, the tools in the marketplace take a bottom-up approach to tackling extraction of information from social media. Users interested in niche information may search by keywords or maintain broad databases of people to follow in hope to capture useful information from social media data. This bottom-up approach of information extraction requires guess work and constant maintenance of lists and keywords.
[0007] Accordingly, improved systems and techniques are needed that detect emerging trends at the social media data level and verify the authenticity of the emerging trends.
SUMMARY
[0008] Systems and techniques for detecting and verifying social media events are disclosed. The system and techniques allow for processing of social media data to extract potentially valuable information in a timely manner and determine the veracity of the detected information.
[0009] One aspect of the disclosure relates to event detection. Event detection involves ingestion and processing of social media data. For example, according to one aspect, a method includes receiving, by an event detecting server, social media data from at least one data source and applying, by the event detecting server, a set of filters to the social media data to generate a data store (i.e. a database or hashmap), the data store comprising a set of identified concepts and corresponding attributes of the social media data. The method also includes selecting, by the event detecting server, one of the set of identified concepts from the database using a corresponding threshold value associated with the attributes of the social media data and generating, by the event detecting server, an event cluster using the selected identified concept. The method may further include deleting by the event detecting server, the selected identified concept from the database.
[0010] In one implementation, the method also includes detecting language of the social media data and removing the social media data that is not in English. In another implementation, the method also includes detecting profanity used in the social media data and removes the social media data containing the detected profanity. In yet another implementation, the method may include detecting at least one of spam, chat and advertisement in the social media data and removing the social media data that contains the at least one detected spam, chat and advertisement.
[0011] In a further implementation, the method includes applying Parts-Of-Speech tagging of the social media data. In an alternative implementation, the method may include analyzing semantic and syntactic structures in the social media data to determine identified concepts in the social media data.
[0012] A threshold value may be used for selection of one of the set of identified concepts from the database and may be associated with a selectable number of distinct attributes (i.e., three distinct attributes) of the social media data related to the identified concept. In one implementation, one of the attributes of the social media data is an authorship value (i.e., the user) and the corresponding threshold value represents a predetermined number (i.e., three) of similar identified concepts associated with different authorship values (i.e., different users).
[0013] In yet a further implementation, the method includes but is not limited to generating a newsworthy score, a topic classification, a summary, and a credibility score for each cluster and its corresponding data.
[0014] In one implementation, for example, the method further includes generating a verification score for each cluster and its corresponding data, the verification score is indicative of the veracity or accuracy of each assertion in the cluster. The veracity score and event clusters may be provided to the user on a graphical user interface.
[0015] In one implementation, the veracity score is determined by analyzing user category, social media level and event features.
[0016] The user category comprises, but is not limited to, determining at least one of name of author, description of author, URL of author, location of author, location of the author matching the location of the event, author being a witness to the event, protection level of the author's account, and verification of the author, associated with each item of the social media data.
[0017] The social media level comprises, but is not limited to, determining at least one of multimedia, url, elongated word, url from news source, and word sentiment associated with the social medial data.
[0018] The event features comprises, but is not limited to, determining at least one of topic of the event and portion of the social media that deny, believe or question the event associated with each item of the social media data.
[0019] In a further implementation, wherein the social media data is twitter data, the event features further comprises determining at least one of a count of the most retweeted tweets, a frequency of retweeted tweets and a frequency of hashtags associated with each item of the social media data.
[0020] Systems, devices, as well as articles that include a machine-readable medium storing machine-readable instructions for implementing the various techniques, are disclosed. Details of various implementations are discussed in greater detail below.
[0021] One advantage relates to accuracy and speed. For example, in one implementation, using the above systems and techniques, collective users may be able to predict the veracity of an event with approximately 85% accuracy and faster than mainstream media can confirm the same information.
[0022] Additional features and advantages will be readily apparent from the following detailed description, the accompanying drawings and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an exemplary architectural diagram of the system;
[0024] FIG. 2 is an exemplary event processing server;
[0025] FIG. 3 a is an exemplary flow chart of one implementation of the disclosure;
[0026] FIG. 3 b is an exemplary flow chart of another implementation of the disclosure;
[0027] FIG. 4 a illustrates exemplary elements in a veracity calculation;
[0028] FIG. 4 b illustrates exemplary elements in an alternative verification calculation;
[0029] FIG. 5 a illustrates an exemplary processing of an item of social media data;
[0030] FIG. 5 b illustrates an example table representation of mapping key concepts to the respective social media data;
[0031] FIG. 5 c illustrates an example database representation in relation to the exemplary social media data of FIG. 5 a;
[0032] FIG. 5 d illustrates an example unit cluster;
[0033] FIG. 5 e illustrates an exemplary ingested data;
[0034] FIGS. 5 f -5 k is an exemplary metadata of ingested data in FIG. 5 e;
[0035] FIGS. 5 l -5 n is an exemplary metadata of an event detected cluster with ingested data of FIG. 5 e as one of the related unit data;
[0036] FIG. 6 a illustrate default event detected clusters viewable through an exemplary graphical user interface (GUI);
[0037] FIG. 6 b illustrate exemplary event detected clusters viewable through an exemplary graphical user interface (GUI);
[0038] FIG. 6 c illustrate a selected event detected cluster viewable through an exemplary graphical user interface (GUI); and
[0039] FIG. 7 a -7 e illustrate additional filters on event detected clusters available through an exemplary graphical user interface (GUI).
DETAILED DESCRIPTION
[0040] In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific implementations in which the disclosure may be practiced. It is to be understood that other implementations may be utilized and structural changes may be made without departing from the scope of the present disclosure.
[0041] FIG. 1 shows an exemplary system 100 for detecting and verifying an event from social media data. As shown in FIG. 1 , in one implementation, the system 100 is configured to include an event detection server 110 that is in communication with a social media platform 180 over a network 160 . The system 100 further comprises an access device 170 that is in communication with an event processing server 210 over the network 160 . Further details of an exemplary event processing server 210 are illustrated in FIG. 2 . The event detection server 110 is in communication with the event processing server 210 over the network 160 . Access device 170 can include a personal computer, laptop computer, or other type of electronic device, such as a mobile phone, smart phone, tablet, PDA or PDA phone. In one implementation, for example, the access device 170 is coupled to I/O devices (not shown) that include a keyboard in combination with a point device such as a mouse for sending an event request to the event processing server 210 . Preferably, the access device 170 is configured to include a browser 172 that is used to request and receive information from the event processing server 210 . Communication between the browser 172 of the access device 170 and event processing server 210 may utilize one or more networking protocols, which may include HTTP, HTTPS, RTSP, or RTMP. Although one access device 170 is shown in FIG. 1 , the system 100 can support one or multiple access devices.
[0042] The network 160 can include various devices such as routers, servers, and switching elements connected in an Intranet, Extranet or Internet configuration. In some implementations, the network 160 uses wired communications to transfer information between the access device 170 and the event processing server 210 , the social media platform 180 and the event detection server 110 . In another implementation, the network 160 employs wireless communication protocols. In yet other implementations, the network 160 employs a combination of wired and wireless technologies.
[0043] As shown in FIG. 1 , in one implementation, the event detection server 110 , may be a special purpose server, and preferably includes a processor 112 , such as a central processing unit (‘CPU’), random access memory (‘RAM’) 114 , input-output devices 116 , such as a display device (not shown), and non-volatile memory 120 , all of which are interconnect via a common bus 111 and controlled by the processor 112 .
[0044] In one implementation, as shown in the FIG. 1 example, the non-volatile memory 120 is configured to include an ingestion module 122 for receiving social media data from the social media platform 180 . Exemplary social media platforms are, but not limited to, Twitter®, Reddit®, Facebook®, Instagram® or LinkedIn®. As used herein, the phase “ingested data” refers to received social media data, which may be but is not limited to, tweets and/or online messages, from the social media platform 180 .
[0045] The non-volatile memory 120 also includes a filtering module 124 for processing ingested data. In one implementation, processing of the ingested data may comprise but is not limited to, detecting language of the ingested data and filtering out ingested data that contains profanity, spam, chat and advertisements.
[0046] The non-volatile memory 120 is also configured to include an organization module 126 for analyzing semantic and syntactic structures in the ingested data. In one implementation, the organization module 126 may apply part-of-speech tagging of the ingested data. In another implementation, the organization module 126 detects key concepts included in the ingested data.
[0047] As shown in the FIG. 1 example, the non-volatile memory 120 may also be configured to include a clustering module 128 for storing key concepts identified by the organization module 126 into a database, an example of which may be but is not limited to a hashmap, and generating an event detected cluster upon reaching a threshold of distinct ingested data containing common key concepts.
[0048] The non-volatile memory 120 is also further configured to include a topic categorization module 131 for classifying the event detected cluster by topics; a summarization module 132 for selecting a representative description for the event detected cluster; and a newsworthiness module 133 for determining a newsworthy score to indicate the importance of the event detected cluster.
[0049] The non-volatile memory 120 is also configured to include an opinion module 134 for detecting if the each ingested data in the event detected cluster contains an opinion of a particular person or is factual (e.g., non-opinionated tone), and a credibility module 135 , for determining the credibility score of the ingested data. In one implementation, the credibility score is associated with three components: user/source credibility: who is providing the information, cluster credibility: what is the information, and tweet credibility: how is the information related to other information.
[0050] The non-volatile memory 120 is further configured to include verification module 150 for determining the accuracy of the event detected cluster. In one implementation, verification may be done by a veracity algorithm which generates a veracity score. In another implementation, the verification module 150 may generate a probability score for an assertion being true based on evidences collected from ingested data.
[0051] The non-volatile memory 120 is further configured to include a knowledge base module 152 for developing a database of information pertaining to credible sources and stores the information in a knowledge base data store 248 ( FIG. 2 ).
[0052] As shown in the exemplary FIG. 1 , a data store 140 is provided that is utilized by one or more of the software modules 124 , 126 , 128 , 131 , 132 , 133 , 134 , 135 , 150 , 152 to access and store information relating to the ingested data. In one implementation, the data store 140 is a relational database. In another implementation, the data store 140 is a file server. In yet other implementations, the data store 140 is a configured area in the non-volatile memory 120 of the event detection server 110 . Although the data store 140 shown in FIG. 1 is part of the event detection server 110 , it will be appreciated by one skilled in the art that the data store 140 can be distributed across various servers and be accessible to the server 110 over the network 160 . As shown in FIG. 1 , in one implementation, the data store 140 is configured to include a filtered data store 141 , an organization data store 142 , a cluster data store 143 , a topic categorization data store 144 , a summarization data store 145 , a newsworthiness data store 146 , an opinion fact data store 147 , a credibility data store 148 and a veracity data store 154 .
[0053] The filtered data store 141 includes ingested data that has been processed by the filtering module 124 . For example, in one implementation, the ingested data processed by filtering module 124 may be English language tweets that do not contain profanity, advertisements, spam, chat or advertisement.
[0054] The organization data store 142 includes ingested data that has been processed by the organization module 126 . In one implementation, the ingested data in organization data store 142 may include parts-of-speech tagging notations or identified key concepts, which are stored as a part of ingested data metadata.
[0055] The cluster data store 143 includes ingested data that has been processed by filtering module 124 and organization module 126 and is queued to be formed into a cluster. In a further implementation, the cluster data store 143 may also contain a data store or database of key concepts (e.g. hashmap) identified by the organization module 126 matched to corresponding ingested data. As used herein with relation to the database of key concepts, ingested data (e.g., tweets and/or online messages) may also be referred to as unit data.
[0056] The topic categorization data store 144 includes the classification of the event detected cluster determined by the topic categorization module 131 . Exemplary topics may include but are not limited to business/finance, technology/science, politics, sports, entertainment, health/medical, crisis(war/disaster), weather, law/crime, life/society, and other.
[0057] The summarization data store 145 includes a selected unit data that is representative of the event detected cluster as determined by the summarization module 132 .
[0058] The newsworthiness data store 146 includes the newsworthy score computed by newsworthiness module 133 . For example, a higher score would imply that the event detected cluster is likely to be important from a journalistic standard.
[0059] The opinion data store 147 includes information pertaining to the determination by the opinion module 134 of whether a given unit data comprises an opinion of a particular person or an assertion of a fact.
[0060] The credibility data store 148 includes a credibility or confidence score as determined by the credibility module 135 .
[0061] The veracity data store 154 includes metrics generated by the verification module 150 regarding the level of accuracy of the event detected cluster. In one implementation, it may be the veracity score determined through a veracity algorithm. In another implementation, it may be a verification score indicating the probability of accuracy based on all the evidences collected from social media.
[0062] In a further implementation, as shown in FIG. 1 , the Event Processing Server 210 includes a processor (not shown), random access memory (not shown) and non-volatile memory (not shown) which are interconnected via a common bus and controlled by the processor. In one implementation, the Event Processing Server 210 is responsible for storing processed information generated or to be used by the Event Detection Server 110 . In another implementation, the Event Processing Server 210 also communicates directly with the user. The Event Processing Server 210 is further illustrated in relation to FIG. 2 .
[0063] It should be noted that the system 100 shown in FIG. 1 is one implementation of the disclosure. Other system implementations of the disclosure may include additional structures that are not shown, such as secondary storage and additional computational devices. In addition, various other implementations of the disclosure include fewer structures than those shown in FIG. 1 .
[0064] Turning now to FIG. 2 , the Event Processing Server 210 in one implementation contains a web server 220 with a non-volatile memory 230 and a UI (user interface) module 232 .
[0065] The UI module 232 communicates with the access device 170 over the network 160 via a browser 172 . The UI module 232 may present to a user through the browser 172 detected events clusters and their associated metadata. Exemplary associated metadata may be but are not limited to the topic, newsworthiness indication and verification score associated with one or more event detected clusters.
[0066] The event processing server 210 may further comprise a data store 240 to host an ingested data store 242 , a generated cluster data store 244 , an emitted data store 246 and the knowledge base data store 248 .
[0067] The ingested data store 242 includes ingested data received from social platform 180 and processed by ingestion module 122 .
[0068] The generated cluster datastore 244 includes the event detected clusters that have been processed by modules 122 , 124 , 126 , 128 , 131 , 132 , 133 , 134 , 135 and 150 .
[0069] The emitted data store 246 includes key concepts and corresponding ingested data that were discarded by the clustering module 128 , as explained in relation to steps 330 - 332 of FIG. 3 a . In an alternative implementation, the emitted data store may be located in the event detection server 110 .
[0070] The knowledge base data store 248 includes a list of credible sources as determined by knowledge base module 152 .
[0071] In one implementation, the Event Processing Server 210 communicates with the Event Detection Server 110 over the network 160 . In another implementation, the Event Processing Server 210 is included in the nonvolatile memory 120 of Event Detection Server 110 . In yet another implementation, the Event Processing Server 210 is configured to communicate directly with the Event Detection Server 110 . An exemplary event processing server 210 may be but is not limited to MongoDB® or ElasticSearch®.
[0072] Referring now to FIG. 3 , an exemplary method 300 of detecting and verifying social media events is disclosed. As shown in the FIG. 3 , at step 302 , information from social media platform 180 is retrieved by the ingestion module 122 of event detection server 110 . In one implementation, the ingestion module 122 may include scripts or code that interface with the social media platform 180 application API. The scripts or code are also able to request and pull information from the APIs. In another implementation, the ingestion module 122 may determine the location of the ingested data and the user and append location information as metadata to the ingested data.
[0073] Next at step 304 , upon receiving the ingested data, the ingestion module 122 stores the ingested data into the ingested data store 242 of event processing server 210 . In a further implementation, metadata may also be generated by the ingestion module 122 and appended to the ingested data prior to storage in the ingested data store 242 .
[0074] In an alternative implementation, the knowledge base module 152 may compile the list of credible sources using information gathered from the ingested data. The knowledge base module 152 stores the list of credible sources in the knowledge base data store 248 . In one implementation, the knowledge base module 152 may analyze user profiles from the ingested data to capture information such as user affiliations or geography to be used for compilation of the list of credible sources. In a further implementation, the knowledge base module 152 takes established credible users and reviews lists generated by the user for relevant information that may be used to generate the list of credible sources. For example, if a credible user has a tech list containing a list of tech users, user IDs and related information (e.g., a related tech list associated with the user ID) associated with the tech users are also mined for information. The knowledge base module 152 continually updates knowledge base data store 248 as further social media data are ingested and may be evaluated at a predetermined frequency to ensure the information is current.
[0075] Continuing onto step 306 , the filtering module 124 retrieves the ingested data from ingested data store 242 and processes the ingested data. Exemplary processing by the filtering module 124 may include language detection and profanity detection. In one implementation, the filtering module 124 determines the language of the ingested data and eliminates ingested data that are not in English. In an alternative implementation, elimination of ingested data can be for other languages.
[0076] The filtering module 124 may also detect profane terms in the ingested data and flag the ingested data that contains profanity. Ingested data containing profanity is then eliminated by the filtering module 124 . In one implementation, the detection of profanity is based on querying a dictionary set of profane terms.
[0077] In a further implementation, the filtering module 124 may utilize a classification algorithm that removes ingested data that is recognized to be spam, chat or advertisements. Exemplary indication of spam would be ingested data saying “follow me @xyz”. Exemplary chat in ingested data may be general chatter about daily lives like “good morning”. Exemplary advertisements in ingested data may contain language such as “click here to buy this superb T-shirt for $10.” In one implementation, the classification algorithm is based on a machine learning model that has been trained on a number of features based on language (i.e., terms used in constructing the data), message quality (i.e., presence of capitalization, emoticons), user features (i.e., average registration age). Exemplary machine learning models include, but are not limited to, Support Vector Machines, Random Forests, and Regression Models. The filtered ingested data is then stored in filtered data store 141 .
[0078] Once filtering has been completed by the filtering module 124 , at step 308 , the organization module 126 retrieves the now filtered ingested data from filtered data store 141 and detects key concepts in the ingested data. In one implementation, the organization module 126 detects semantic and syntactic structures in the ingested data.
[0079] In another implementation, the organization module 126 may apply part-of-speech tagging, through a Part-Of-Speech tagger, on the ingested data. For example, the organization module 126 recognizes verbs, adverbs, proper nouns, and adjectives in the ingested data. In a further implementation, there may be a predefined list of terms used for recognition by the organization module 126 that includes, but are not limited to, crisis terms like “fire,” “tornado”, or “blast”. The predefined list of terms may also be further customized based on concepts that are not proper nouns but are a good proxy for the main context of the ingested data.
[0080] Part-of-speech tagging notations or identified key concepts may then be stored into the organization data store 142 . In one implementation, the Part-of-speech tagging notations or identified key concepts may be appended to the ingested data metadata and stored into the organization data store 142 .
[0081] All key concepts, proper nouns, hashtags, and any list terms found in the ingested data are designated as a ‘markable’. In a further implementation, the markable may be further concatenated to produce markables that are more meaningful. For example, if “New” followed by “York” has been identified as a markable, then the terms are concatenated to indicate the revised markable as “New_York” and removing individual “New” and “York”.
[0082] Once the key concepts are identified by the organization module 126 , the clustering module 128 at step 310 , obtains organized ingested data from organization data store 142 and creates a database of key concepts with a reference to the corresponding ingested data. In one implementation, the referenced corresponding ingested data maybe in the form of a unit data. This database is then stored in cluster data store 143 .
[0083] At step 312 , each key concept has a predefined time frame to grow to a minimum count of unit data required to be considered an unit cluster or else it is discarded. An exemplary threshold count, may be but is not limited to, three (3) unit data for a key concept. To illustrate, if collective users (i.e., authorship value) are mentioning similar key concepts in their social media data, there maybe a likelihood of an emerging event.
[0084] Once a threshold number of unit data containing common markables have been met, in step 314 , the clustering module 128 generates a unit cluster. In a further implementation, the unit data corresponding to the markable are generated as the unit cluster in step 314 and are removed from the database in step 316 .
[0085] However, if the threshold has not been met, at step 330 , the markables in the database may be reviewed. For markables that have not exceeded a predefined time window, (i.e. 2 hours), the process starts again from step 302 with newly ingested data. To illustrate, this may be social media information that is so fresh that other collective users did not get to mention it yet.
[0086] However, markables that never grow to the minimum threshold of unit data after a predefined time window (i.e., 2 hours) are removed from the database at step 332 . The discarded markables and unit data may be sent to the emitted data store 246 along with other metadata about it. To illustrate, social media information that no other users are mentioning might not be an event of importance to a professional consumer.
[0087] Returning to step 314 , once the unit cluster is generated, its corresponding markables and unit data are removed from the database in step 316 . The newly generated unit cluster is checked against a set of previously generated event detected clusters, at step 318 . The set of previously generated event detected clusters may be located in the cluster data store 143 . In an alternative implementation, generated clusters may be located in the generated cluster data store 244 of the event processing server 210 .
[0088] If there is not a match to the set of previously generated event detected clusters, continuing onto step 324 , the unit cluster is determined to be a new event detected cluster by the clustering module 128 and is stored into cluster data store 143 .
[0089] However, if there is a match to existing generated event detected clusters, based on a set of predefined rules, at step 320 , a decision to either merge two similar clusters or keep them as two separate clusters is made. In one implementation, the decision to merge may be based on the same underlying concepts.
[0090] If the decision is to merge two similar clusters, continuing onto step 322 , the cluster module 128 merges the clusters and stores the merged event detected cluster is stored into cluster data store 143 . For example, if social media information is the same as a previously detected event, the social media information is then merged with the previously detected event.
[0091] However, if the clusters are to remain distinct, continuing onto step 324 , the unit cluster is determined to be a new event detected cluster and is stored into cluster data store 143 . For example, social media information that is distinct from the previously detected events maybe an event of importance to a professional consumer and should be noted as such, therefore the unit cluster is considered by the clustering module 128 as an event detected cluster.
[0092] Turning now to FIG. 3 b , in a further implementation, upon storing the event detected cluster, at step 342 , enrichments may be applied to the event detected cluster. Exemplary enrichments are, but not limited to, topic categorization, summarization, newsworthiness, opinion and credibility.
[0093] As mentioned previously, the topic categorization module 131 may determine one or more classification for the event detected cluster. The classification may be a taxonomy of predefined categories (i.e., politics, entertainment). The classification is added to the metadata for the event detected cluster.
[0094] The summarization module 132 may select a unit data in the event detected cluster that best describes the cluster. The selected unit data is used as a summary for the event detected cluster. In a further implementation, the summarization module 132 may also utilize metrics such as the earliest unit data or a popular unit data in the generation of the summary for the event detected cluster. The summary is added to the metadata for the event detected cluster.
[0095] The newsworthiness module 133 uses a newsworthiness algorithm to calculate a newsworthy score. The newsworthy score is an indication of the importance of the event detected cluster from a journalistic standard. For example, an event detected cluster concerning an airplane crash for a breaking news event is considered more important than a cluster around a viral celebrity picture. In one implementation, the newsworthiness algorithm is a supervised Machine Learning algorithm that has been trained on a newsworthy set of ingested data and predicts a newsworthy score for any ingested data that is passed through it. The newsworthy score is added to the metadata for the event detected cluster.
[0096] The opinion module 134 determines if the each unit data in the event detected cluster contains an opinion of a particular person or an assertion of a fact. In one implementation, for unit data that are an assertion of fact, a score indicative of an assertion as a fact is also assigned to the unit data and likewise for an opinion. In a further implementation, the opinion module 134 executes in a two stage process. In the first stage, a rule based classifier is applied that uses simple rules based on presence/absence of certain types of opinion/sentiment words, and/or usage of personal pronouns to identify opinions. In the second stage, all unit data that are indicated to be non-opinions are passed through a bag-of-words classifier that has been trained specifically to recognize fact assertions. The determination of fact or opinion is then stored as a part of the event detected cluster metadata.
[0097] The credibility module 135 determines the confidence score of each unit data in the event detected cluster. In one implementation, the confidence score is associated with three components: source credibility, cluster credibility, and tweet credibility. The score and information generated by the components are then stored as a part of the event detected cluster metadata.
[0098] Source credibility relates to the source of the unit data. If the source is a credible source, for example, an authority such as the White House stating an event is more credible than a random unknown user. In one implementation, source credibility is measured by an algorithm that uses features like, but not limited to, age of the user, description, and presence of a profile image of the social media account.
[0099] Cluster credibility relates to what the information is. Typically, detected events clusters containing genuine events may have different growth patterns from fake detected events clusters, such as a fake event might be driven by negative motivations like purposely spreading rumors. A supervised learning model is used based on historical data that identifies likelihood of the event detected cluster being true or false based on growth patterns.
[0100] Tweet credibility relates to the content of the individual tweets in the unit data and the language being mentioned therein. In one implementation, the unit data is evaluated against a set of textual words trained on credible and noncredible unit data.
[0101] Next, at step 344 , the verification module 150 analyzes the enrichments applied to the event detected cluster and its related unit data to determine the level of accuracy of the event detected cluster. In one implementation, the verification module 150 may generate a veracity calculation based on three categories: user, tweet-level or social media data level and event, from the unit data. In another implementation, the verification module 150 may compute a probability of the propagating rumor being true using extracted language, user and other metadata features from event detected cluster and its related unit data. Verification is explained in greater detail in relation to FIGS. 4 a and 4 b.
[0102] Finally, at step 346 , the enriched event detected cluster is then stored in generated cluster data store 244 of the event processing server 210 .
[0103] FIG. 4 a illustrates an exemplary description of categories used in a veracity calculation. The first category for consideration pertains to a user category. In one implementation, the user features 402 a are boolean and may include, but are not limited to: name, description, url, location, matches cluster location, witness, protected (i.e., private or not), verified, as illustrated in FIG. 4 a . The user category captures user specific information gathered from their social media profile. Exemplary features like location or url can weigh into the credibility of the user. For example, if the user is anonymous for their location, it is hard to determine the accuracy of what they are saying. However, if their location matches the location of the event detected cluster, the incident as gathered from the ingested data might be viewed in a more favorable way as being accurate.
[0104] The secondary category for consideration is on the social media level. In one implementation, the social media features 402 b of boolean type, may include, but are not limited to: multimedia, elongated word, url and news url, as illustrated in FIG. 4 a . The social medial category may further include numerical type: number sentiment positive words, number sentiment negative words, and sentiment score, which is of numerical type. For example, if a user is attaching a picture or multimedia to the reported incident, that can be a clear indication of the accuracy of the reporting on the social media data. In another example, the type of words used by the user, especially elongated words, i.e. “OMMMMMMGGG!!” might convey the user's shock related to the event and lend itself to a more credible event. However, if the user uses a url in the social media data, the user might be sharing by reiteration. In a further implementation, the sentiment of the ingested data is also examined. The ingested data may be checked against a set of positive and negative words for an indication of the sentiment. As an example, if the event detected cluster pertains to a disaster, the general tone of the ingested data should be negative.
[0105] The third category for consideration is event features. In one implementation, the event features 402 c may include: event topic, which may be categorical type, and highest retweet count, retweet sum, hashtag sum, negation fraction, support fraction, question fraction, which may be of numerical type, as illustrated in FIG. 4 a . In one implementation, if the ingested data are twitter tweets, the retweeting count and sum are valued, with the assumption that the count correlates to the popularity of the event which weighs more in favor of being accurate. In another implementation, hashtags may also be an indicator of the event. For example, sports related ingested data may contain many hashtags, while a disaster related ingested data may not have many hashtags, as there might not be time to list so many hashtags when a disaster is unfolding at the location of the user. In yet another implementation, the algorithm also takes into consideration the fraction of ingested data that deny, believe or question the event.
[0106] The verification module 150 generates a matrix that is aggregated based on the three categories to generate a veracity score between −1 to 1, ranging from a false rumor to a true story. In one implementation, as illustrated in FIG. 5 n , the veracity score 550 may be added to the metadata of the event detected cluster. In a further implementation, as illustrated in FIG. 6 b , the veracity score 614 may be presented to the user in the form of circle representations.
[0107] FIG. 4 b illustrates the determination by the verification module 150 a probability score for the event detected cluster being true based on information collected from social media. In the FIG. 4 b example, Twitter is used as an exemplary social media platform. In one implementation, the verification module 150 first determines if the unit data of the event detected cluster is an expert type assertion or a witness type assertion.
[0108] Expert type assertions are assertions that likely to be made only by people or organizations that are considered authoritative for that assertion. An exemplary expert type assertion may be the company Apple® asserting that they will be releasing a new iPhone®. The verification module 150 may invoke the knowledge base module 152 to determine if the identified user of the unit data (i.e., Apple®) is a credible source and awards a higher score if the unit data is originating from a credible source.
[0109] In a further implementation, if the user of the unit data is from the list of credible sources determined by the knowledge base module 152 as authoritative on that topic, then a higher score is given. If the user of the ingested data is not authoritative, then other experts and their recent tweets are considered by the knowledge base module 152 to collect or negate the user assertion.
[0110] Witness type assertions are assertions any random user may potentially make. These include crises type of events (for example, User 123 assets that an explosion took place in a particular area.) In one implementation, the verification module 150 compares either the topic or the geography of the unit data against other unit data from the same geographic area. If other users are not mentioning the same assertion during the same time period, then a lower score may be assigned.
[0111] In yet a further implementation, a knowledge base of organizations as determined by the knowledge base module 152 may also be considered. Social media data from the collective knowledge base of organizations may also be processed by the Event Detection Server 110 to determine if they are discussing about a similar assertion and are used to compare with the current unit data to determine level of authenticity.
[0112] The verification module 150 may then assign a probability that indicates its likeliness to be true or false. In one implementation, the verification module may algorithmically compute a score between −1 and 1, where 0 is neutral depicting our lack of information in the matter, 1 depicts highest level of confidence in the assertion being true and −1 being the highest level of confidence in it being false. For example, if information from very credible sources have confirmed that an assertion is true, then its score is likely 1. However for cases that we cannot find concrete evidences for near accuracy of its authenticity or truthfulness, the score will then fall between −1 and 1 depending on the type of evidences collected. The confidence may be re-evaluated when new evidences are included in its assessment.
[0113] Referring now to FIG. 5 a , an exemplary ingested data is illustrated. In one implementation, the ingested data may be but is not limited to a tweet. The organization module 126 analyzes semantic and syntactic structures in the ingested data to identify key concepts. In this example, terms 502 a - 502 d , such as “confederate flag” “rally” “Linn Park” “Birmingham” are identified key concepts by organization module 126 . Although four key concepts are identified in this example, there may be n number of terms identified by the organization module 126 . In one implementation, the key concepts are stored in a database 500 , with the key concepts designated as a “markable” and the corresponding originating ingested data as a “unit data”, as illustrated in FIG. 5 b . As shown in FIG. 5 b , there may be a column 504 for n number of markables, each with corresponding column 506 pertaining to n number of unit datas. In one implementation, the database may be a hash table or a hashmap.
[0114] Turning to FIG. 5 c , an example of the database using information from FIG. 5 a is disclosed. In this example, the ingested data in FIG. 5 a is represented as Unit data 1 . The identified key concepts 502 a - 502 d are listed as markable 508 a - 508 d in the markable column 504 , and the originating ingested data as Unit data 1 is also noted in the corresponding column 506 . As additional ingested data are processed in accordance with steps 302 - 310 of FIG. 3 a , each xth ingested data is represented as “Unit data x”. For example, the second ingested data may be represented as “Unit data 2 ”. If “Unit data 2 ” also contains the markable “Linn Park”, it may be added to the row for Linn Park in the database 500 and “Unit data 2 ” will be noted along with “Unit data 1 ” in the corresponding column 506 . Once the unit data for a markable grows and reaches a predefined threshold, it is then emitted as an event detected cluster. To put it a different way, this is an indication that multiple users are reporting similar events and therefore, may be an emerging event.
[0115] Turning to FIG. 5 d , an exemplary unit cluster is illustrated. In one implementation, the unit cluster becomes the event detected cluster if the clustering module 128 determines that there is not already an existing cluster, or if there is an existing cluster but based on predetermined rules, the clustering module 128 determines not to merge with an existing cluster. The unit cluster comprises a threshold number n of n unit data (e.g., 3 unit clusters).
[0116] FIG. 5 e is another exemplary ingested data in the form of a tweet. This ingested data is one of the many unit data from an exemplary event detected cluster pertaining to “Mugabe: Foreign firms ‘stole diamonds’: Zimbabwean President Robert Mugabe accuse foreign mining companies of . . . ”. This ingested data was also selected by the summarization module 132 as a representative summary of the event detected cluster.
[0117] FIGS. 5 f -5 k are exemplary metadata of ingested data in FIG. 5 e . The ingested data comprises default metadata generated by the social media platform (i.e, twitter metadata) as illustrated in FIGS. 5 f -5 h and 5 k . The Event Detection Server generates additional metadata and is appended to metadata of ingested data described above, and is illustrated in FIGS. 5 i and 5 j.
[0118] Referring now to FIG. 5 i , the added metadata includes, but is not limited to, the credibility score 535 as determined by the credibility module 135 ; the opinion score 534 as determined by the opinion module 134 ; the profanity indicator 524 as determined by filtering module 124 and the markables 526 as determined by organization module 126 .
[0119] FIGS. 5 l -5 n are an exemplary metadata of an event detected cluster with ingested data of FIG. 5 e as one of the related unit data.
[0120] In FIG. 5 l -5 m , the cluster metadata includes, but is not limited to, the newsworthiness score 533 as determined by newsworthiness module 133 ; the topic 531 as determined by topic categorization module 131 ; the summary 532 as determined by summarization module 132 and markables 504 a as identified in the unit data by the organization module 126 and selected to form the event detected cluster. Each markables 504 a may also include the respective unit data 506 a information.
[0121] Continuing on to FIG. 5 n , the cluster metadata includes, but is not limited to, unit data 506 b forming the event detected cluster and the veracity score 550 as computed by verification module 150 .
[0122] Now turning to FIG. 6 a , an exemplary graphical user interface (GUI) available through a browser 172 of access device 170 is disclosed. In one implementation, the browser 172 includes an application interface 600 that includes a plurality of columns for viewing of a list of event detected clusters pertaining to channels 602 . Within each channel are the event detected clusters relating to the topic of the channel.
[0123] In one implementation, in the FIG. 6 a example, there may be channel 602 a for “newest” and another channel 602 b for “trending”. However, although only two channels are presented on the application interface 600 to the user in this example, there may be n number of channels displayed on the application interface 600 . The default channels provided by the application interface 600 allow the user to be notified of events that might be new or trending without having to search by key terms.
[0124] In another implementation, continuing onto FIG. 6 b , a user through the browser 172 of access device 170 may enter a search term in search field 601 to tailor the application interface 600 to their needs. The UI module 232 of Event Processing Server 210 will then retrieve any event detected clusters matching the user's search term from the generated cluster datastore 244 . The results are rendered by the UI module 232 and presented to the user through browser 172 under channel 602 a of program interface 600 , with the channel representing the search term. As shown in FIG. 6 b example, channel 602 c representing the search term “GOP” and channel 602 d for “Democrats” may be presented for viewing.
[0125] In one implementation, the indication 604 provided before the text of the event detected cluster depicts the number of unit data in the event detected cluster. In a further implementation, there may be additional designation 605 indicating the event detected cluster importance based on the topic to a professional consumer (e.g. topic relating to crises, conflicts (political or geopolitical) or criminal activity).
[0126] In a further implementation, the event detected cluster may also be presented with the topic 606 as determined by topic categorization module 131 ; categories 608 which may be customized terms; summary 616 as determined by summarization module 132 . The event detected cluster may also contain concepts 610 , which are the markables from the unit data that formed the event detected cluster, as determined by organization module 126 .
[0127] The event detected cluster may further be presented with the hashtags 612 used in the ingested data as detected by the organization module 126 , newsworthiness indication 618 as determined by newsworthiness module 133 . In one implementation, newsworthiness indication 618 might be depicted as a filled in star.
[0128] The event detected cluster may also be presented with veracity score 614 as determined by verification module 150 . In one implementation, the veracity score may be in the form of filled-in circles indicative of the strength of the veracity determination, with 5 solid circles as near accurate.
[0129] In yet another implementation, the user may select create new channel 620 based on concepts in an event detected cluster. The newly created channel is based on identified concepts 610 .
[0130] Using the critical event detected cluster as an example, the selection of the cluster is illustrated in FIG. 6 c . The set of unit data 632 a - 632 n corresponding to the selected event detected cluster 631 is presented. In a further implementation, the user may utilize link 634 to view a specific unit data.
[0131] Returning back to FIG. 6 b , in another implementation, channel options 622 allows for filtering of the event detected cluster results presented by UI module 232 onto browser 172 of the access device 170 . The UI module 232 receives the filter designation as selected by the user in the application interface 600 and processes the request in accordance with the filters illustrated in relation to FIG. 7 a - 7 e.
[0132] In one implementation, as shown in FIG. 7 a , filtering is available based on topic 710 , sort method 720 , category 730 and advance 740 filtering.
[0133] FIG. 7 b illustrates an exemplary topic filter 710 . The topic filter 710 contains list of topic filters 712 a - 712 n . They may be, but not limited to, topics pertaining to: business/finance, crisis, entertainment, hard news, health/medical, law/crime, life/society, politics, sports, technology, weather, or other as identified by the topic categorization module 131 .
[0134] FIG. 7 c illustrates an exemplary sort filter 720 . The sort filter 720 contains options 722 a - 722 n and they may be but are not limited to sorting by: newest, updated, most popular, tending, newsworthy, and veracity.
[0135] FIG. 7 d illustrates an exemplary category filter 730 . The category filter 730 contains a list of category filters 732 a - 732 n . The category options may be but are not limited to: breaking news, conflict, disaster, dow, financial risks, geopolitical risks, legal, legal risks, markets, oil, politics, shootings, U.S. elections.
[0136] FIG. 7 e are the advanced options upon selection of advance 740 on application interface 600 . In one implementation, the advance options for the selected channel may be, reset defaults 744 , timeline 746 with a time frame selection, minimum posts 748 count, and three levels of strict 760 , medium 762 or loose 764 for fact 750 , newsworthiness 752 and veracity 754 .
[0137] FIGS. 1 through 7 e are conceptual illustrations allowing for an explanation of the present disclosure. Various features of the system may be implemented in hardware, software, or a combination of hardware and software. For example, some features of the system may be implemented in one or more computer programs executing on programmable computer. Each program may be implemented in a high level procedural or object-oriented programming language to communicate with a computer system or other machine. Furthermore, each such computer program may be stored on a storage medium such as read-only-memory (ROM) readable by a general or special purpose programmable computer or processor, for configuring and operating the computer to perform the functions described above.
[0138] Notably, the figures and examples above are not meant to limit the scope of the present disclosure to a single implementation, as other implementations are possible by way of interchange of some or all of the described or illustrated elements. Moreover, where certain elements of the present disclosure can be partially or fully implemented using known components, only those portions of such known components that are necessary for an understanding of the present disclosure are described, and detailed descriptions of other portions of such known components are omitted so as not to obscure the disclosure. In the present specification, an implementation showing a singular component should not necessarily be limited to other implementations including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, applicants do not intend for any term in the specification or claims to be ascribed an uncommon or special meaning unless explicitly set forth as such. | Systems and techniques for detecting and verifying social media events are disclosed. The system and techniques allow for processing of social media data to extract potentially valuable information in a timely manner and determine the veracity of the detected information. One implementation of the disclosure relates to event detection. Event detection involves ingestion and processing of social media data. Another implementation of the disclosure relates to verification of a detected event and generating a verification score. | 6 |
BACKGROUND OF THE INVENTION
Considerable research and resources have been devoted to oncology and antitumor measures including chemotherapy. While certain methods and chemical compositions have been developed which aid in inhibiting, remitting, or controlling the growth of tumors, new methods and antitumor chemical compositions are needed. The prevention and control of fungal growth is also of considerable importance to man, and much research has been devoted to the development of antifungal measures.
It has been found that some natural products and organisms are potential sources for chemical molecules having useful biological activity of great diversity. Marine life has been the source for the discovery of compounds having varied biological activities. Some of the United States patents which have issued for such inventions are as follows: U.S. Pat. No. 4,548,814 for didemnins, having antiviral activity, were isolated from a marine tunicate; U.S. Pat. No. 4,729,996 discloses compounds, having antitumor properties, that were isolated from marine sponges Teichaxinella morchella and Ptilocaulis walpersi; U.S. Pat. No. 4,808,590 discloses compounds, having antiviral, antitumor, and antifungal properties, isolated from the marine sponge Theonella sp.; and U.S. Pat. No. 4,737,510 discloses compounds, having antiviral and antibacterial properties, isolated from the Caribbean sponge Agelas coniferin. Clearly, marine sponges have proved to be a source of biological compounds, and a number of publications have issued disclosing organic compounds derived from marine sponges, including Scheuer, P. J. (ed.) Marine Natural Products, Chemical and Biological Perspectives, Academic Press, New York, 1978-1983, Vol. I-V; Faulkner, D. J., (1984) Natural Products Reports 1:551-598; Natural Products Reports (1986) 3:1-33; Natural Products Reports (1987) 4:539-576; Natural Products Report (1988) 5:613-663; J. Am. Chem. Soc. (1985) 107:4796-4798.
The subject invention concerns novel bisindole-imidazole alkaloids. Indole compounds of marine origin have previously been described in Tetrahedron Letters (1984) 25:5047-5048 and J. Am. Chem. Soc. (1982) 104:3628-3635. See also Bartik, K., J. C. Braekman, D. Daloze, C. Stoller, J. Huysecom, G. Vandevyer, and R. Ottinger (1987) Can. J. Chem. 65:2118; and Braekman, J. C., D. Daloze, and C. Stoller (1987) Bull. Soc. Chi. Belg. 96(10):809.
The present invention, utilizing sponges as a source material and supplemented by novel synthetic production methods, has provided the art with a new class of biologically active compounds and new pharmaceutical compositions useful as antitumor and antimicrobial agents.
Other advantages and further scope of applicability of the present invention will become apparent from the detailed descriptions given herein; it should be understood, however, that the detailed descriptions, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent from such descriptions.
BRIEF SUMMARY OF THE INVENTION
The subject invention concerns novel brominated bisindole-imidazole alkaloids and methods for use of these compounds. Specifically exemplified herein are six novel compounds. Three of these compounds--nortopsentin A, nortopsentin B, and nortopsentin C--were isolated from marine sponges Topsentia and Halichondria spp. These compounds, as well as their derivatives, show antitumor and antimicrobial activities. Thus, this new class of compounds and their derivatives and analogs could be used as antitumor and/or antimicrobial agents.
The isolation of the natural products was performed using solvent partition and centrifugal countercurrent chromatography. The final purification of nortopsentin A, B, and C was achieved using HPLC, prep TLC and recrystallization, respectively. The structures of nortopsentins were determined mainly on the basis of their 1 H and 13 C NMR data. The deduced structures of the novel compounds are shown in FIG. 1.
The compounds of the subject invention, including derivatives and salts thereof, have antitumor and antimicrobial properties. Thus, they can be used for the treatment of a number of diseases, including cancer.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows the deduced structures of the novel compounds.
DETAILED DESCRIPTION OF THE INVENTION
The subject invention pertains to novel chemical compounds isolated from marine sponges. These compounds have been shown to possess antitumor and antimicrobial activity. Thus, the subject invention pertains to the compounds themselves, as well as pharmaceutical compositions containing these compounds. Also disclosed and claimed are methods for administering the novel compositions. Various derivatives of these compounds can be produced by known procedures. Simple salts of the compounds described here are also within the scope of the invention. These simple salts could include, for example, the Cl - , Br - , I - , and HSO 4 - salts. As is known by those skilled in the art, these salts can be produced using, for example, anion exchange columns. The parent compounds can be isolated from marine sponges as described below.
Following are examples which illustrate procedures, including the best mode, for practicing the invention. These examples should not be construed as limiting. All percentages are by weight and all solvent mixture proportions are by volume unless otherwise noted.
EXAMPLE 1--ISOLATION OF NORTOPSENTIN A, B, & C
The sponge Spongosorites sp. (80 g), collected at the depth of 630 ft. off Chub Cay, Bahamas, on Aug. 26, 1985, was lyophilized and extracted with methanol-toluene (3:1). The extract was evaporated to dryness and partitioned between ethyl acetate and water. The water soluble fraction was further partitioned with butanol. The combined ethyl acetate and butanol fractions were chromatographed on a Hibar LiChrosorb NH 2 column using HPLC with CHCl 3 --MeOH (5:1) as elution solvent to yield a semi-purified compound, nortopsentin B (3 mg).
Sponge of the genus Halichondria (830 g) was collected at the depth of 1512 ft. off Nassau, Bahamas, on Mar. 15, 1987. The frozen sponge was extracted with 1.5L of methanol four times. The extracts were combined and concentrated under reduced pressure to give a 400 mL of water suspension, which was then extracted with ethyl acetate (300 mL×3). The resulting ethyl acetate fraction was evaporated to dryness to yield a crude fraction (12.02 g). It was found that the majority of the components in this fraction was topsentin and bromotopsentin.
A two-phase solvent system was generated by mixing heptane, ethyl acetate, methanol, and water in a ratio of 4:7:4:3. The crude fraction (12.00 g) was partitioned between 150 ml of the upper phase solvent and 300 ml of the lower phase solvent. The resulting lower layer fraction was extracted with 150 ml of the upper phase solvent three more times. The combined upper layer fractions were evaporated to dryness (5.75 g) and dissolved in 50 ml of the upper phase solvent. The solids were filtered off and the eluant was evaporated to dryness (4.46 g). The residue was dissolved again in 30 ml of the upper phase solvent. After removal of the insoluble material and evaporation of the solvent, 2.75 g of a solid was obtained.
This solid was further fractionated by using centrifugal countercurrent chromatography with two different solvent systems consisting of heptane/ethyl acetate/methanol/water in ratios of 4:7:4:3 and 5:7:4:3. A fraction containing nortopsentin A and a mixture of nortopsentin B and C along with topsentin (400 mg) and bromotopsentin (540 mg) were obtained. Nortopsentin A (250 mg) was purified by HPLC on a Hibar NH 2 column (10×250 mm), using 5:1 chloroform/methanol as eluant. Preparative TLC (Kieselgel 60F 264 , 2 mm thickness, ethyl acetate) afforded a pure nortopsentin C (200 mg) and a fraction containing nortopsentin B. Pure nortopsentin B (250 mg) was finally recrystallized from ethyl acetate/chloroform.
EXAMPLE 2--PHYSICAL AND SPECTRAL DATA OF NORTOPSENTIN A
Nortopsentin A, a colorless oil; HREIMS m/z 453.9426 (calcd. for C 19 H 12 N 4 Br 2 , Δ0.3 mmu); LREIMS m/z 457.9(31.8), 455.9(57.7), 453.9(29.4), 377.0(9.5), 375.1(9.4), 350.0(1.8), 348.0(2.2), 296.1(4.7), 268.1(3.2), 236.0(4.9), 234,0(5.7), 222.0(5.0), 219.9(5.1), 209.0(6.8), 207.0(7.2), 197.0(7.0), 195.0(7.3), 188.6(7.4), 155.1(16.2), 148.1(7.3), 141.0(7.2), 128.0(25.6), 116.1(10.9), 114.1(9.6), 101.0(12.8), 89.0(6.9), 82.0(23.3), 79.9(24.4), 77.0(7.2), 75.1(7.7), 63.1(6.6), 58.1(6.2), 51.0(6.0), 44.1(62.5), 32.0 (52.6), and 28.2(100.0 rel. %); LRFABMS m/z 459, 457, and 455 for (M+H) + ; UV(MeOH) λmax 207.0(ε50,300), 236.0(ε42,300), 277.0(ε26,400), and 310(sh) nm; IR(KBr) 3420, 1615(sh), 1591, 1510, 1448, 1430(sh), 1328, 1248, 1100, 1023, 919, 892, 800, 781, and 757 cm -1 ; 1 H NMR(acetone-d 6 ) δ11.059(1H, brs, D 2 O exchangeable), 10.847(1H, brs, D 2 O exchangeable), 8.469(1H, d, J=8.5 Hz), 7.996(1H, d, J=8.5 Hz), 7.901(1H, d, J=2.1 Hz), 7.795(1H, d, J=2.3 Hz), 7.618(1H, d, J=1.8 Hz), 7.610(1H, d, J=1.8 Hz), 7.530(1H, s), 7.319(1H, dd, J=8.4 Hz), and 7.298(1H, dd, J=8.4, 1.6 Hz); 13 C NMR(acetone-d 6 ) δ143.77(s), 138.46(s), 138.26(s), 133.34(s, br), 125.09(s×2), 125.02(d, J=185 Hz), 123.79(d, J=166 Hz), 123.49(d, J=184 Hz), 123.31(d, J=164 Hz), 123.18(d, J=165 Hz), 122.26(d, J=161 Hz), 116.16(s), 166.10(d, br, J=189 Hz), 115.52(s), 115.24(d, J=166 Hz), 115.18(d, J=166 Hz), 110.71(s), and 108.72(s); 1 H NMR(methanol-d 4 ) δ8.401(1H, d, J=8.5 Hz), 7.718(1H, d, J=8.5 Hz), 7.695(1H, s), 7.609(1H, s), 7.545(1H, d, J=1.7 Hz), 7.536(1H, d, J=1.7 Hz), 7.297(1H, s), 7.245(1H, dd, J=8.5, 1.7 Hz), and 7.196(1H, dd, J=8.5, 1.7 Hz); 13 C NMR(methanol-d 4 ) δ144.31(s), 138,88(s), 138.70(s), 132.67(s, br), 125.59(d, J=183. Hz), 125.38(s), 125.16(s), 124.24(d, J=165 Hz), 123.60(d×2, J=183 and 164 Hz), 122.62(d, J=162 Hz), 121.95(d, J=161 Hz), 117.57(d, br, J=191 Hz), 116,67(s), 116.18(s), 115.39(d, J=166 Hz), 115.30(d, J=166 Hz), 110.04(s), and 108.43(s).
EXAMPLE 3--PHYSICAL AND SPECTRAL DATA OR NORTOPSENTIN B
Nortopsentin B, colorless crystals; decomposed at 250°-270° C.; HREIMS m/z 376.0320(calcd. for C 19 H 13 N 4 Br, Δ0.4 mmu), LREIMS m/z 378.1(55.5), 376.2(56.7), 350.1(2.8), 348.1(2.5), 297.1(19.7), 270.1(5.1), 268.1(5.1), 242,1(3.8), 236.0(6.9), 234.0(6.6), 209.0(4.4), 207.1(4.3), 188.0(6.8), 155.1(37.1), 148.5(26.8), 142.1(10.7), 135.1(11.9), 128.0(47.3), 121.1(9.1), 114.1(12.1), 101.0(28.4), 82.0(46.3), 79,9(50.8), 77.1(16.3), 75.1(17.6), 63.2(9.7), 58.2(19.1), 51.0(15.6), 44.1(100.0), 39.8(23.6), 32.0(100.0), and 28.2(100.0 rel. %); LRFABMS m/z 379 and 377 for (M+H) + ; UV(MeOH) λmax 206.5(ε50,700), 232.0(ε45,200), 278.5(ε25,600), and 310(sh) nm; IR(KBr) 3400, 1620(sh), 1603(sh), 1587, 1562(sh), 1448, 1422, 1364, 1328, 1249, 1238, 1104(br), 1092(sh), 1024, 927(sh), 920, 894, 811, 762, and 743 cm -1 ; 1 H NMR(acetone-d 6 ) δ10.709(1H, brs), 10.378(1H, brs), 8.540(1H, d, J=8.5 Hz), 8.029(1H, brd, J=7.4 Hz), 7.916(1H, d, J=2.7 Hz), 7.743(1H, d, J=2.3 Hz), 7.648(1H, d, J=1.7 Hz), 7.443(1H, dd, J=8.7, 1.3 Hz), 7.426(1H, s), 7.290(1H, dd, J=8.6, 1.8 Hz), 7.152(1H, m), and 7.114(1H, m); 13 C NMR(acetone d 6 ) δ143.38(s), 138.44(s), 137.86(s), 126.34(s), 125.47(s), 124.27(d×2), 123.67(d), 122.45(d), 122.35(d), 120.97(d), 120,15(d), 116.04(s), 115.09(d), 112.30(d), and 109.61(s); 1 H NMR(1:1 acetone-d 6 /methanol-d 4 ) δ8.259(1H, d, J=8.5 Hz), 7.942(1H, brd, J=8.6 Hz), 7.864(1H, s), 7.758(1H, s), 7.616(1H, d, J=1.7 Hz), 7.463(1H, s), 7.429(1H, brd, J= 8.5 Hz), 7.284(1H, dd, J=8.5, 1.7 Hz), 7.165(1H, m) and 7.131(1H, m); 13 C NMR(1:1 acetone-d 6 /methanol-d 4 ) δ143.85(s), 138.58(s), 137.97(s), 132,89(s, br), 126.37(s), 125.50(d), 125.26(s), 124.09(d), 123.24(d), 122.89(d), 122.75(d), 120.75(d), 120.60(d), 118.01(d, br), 116.40(s), 115.45(d), 112.60(d), 109.77(s, br), and 108.86(s).
EXAMPLE 4--PHYSICAL AND SPECTRAL DATA OF NORTOPSENTIN C
Nortopsentin C, a colorless oil; HREIMS m/z 376.0316 (calcd. for C 19 H 13 N 4 Br, Δ0.8 mmu); LREIMS m/z 378.1(95.7), 376.1(100.0), 350.0(5.3), 348.1(5.3), 297.1(20.3), 270.1(6.6), 268.1(6.4), 242.1(5.8), 235.0(5.6), 233.0(4.9), 209.0(8.8), 207.0(8.9), 197.0(7.0), 195.0(7.4), 188.0(9.7), 155.1(45.0), 148.5(38.1), 142.1(14.6), 135.1(14.5), 128.0(51.4), 116.1(19.4), 101.0(35.5), 89.0(15.0), 81.9(30.5), 79.8(30.7), 58.1(28.5), and 53.1(24.5 rel. %); LRFABMS m/z 379 and 377 for (M+H) + ; UV(MeOH) λmax 207.5(ε50,300), 230(sh), 280(sh) and 310(sh)nm; IR(KBr) 3410, 1620(sh), 1598, 1450, 1531(br), 1411(br), 1332, 1245, 1128, 1100, 1023, 920, 896, 800, and 745 cm -1 ; 1 H NMR(acetone-d 6 ) δ10.598(2H, brs), 8.552(1H, brd, J=8.7 Hz), 8.038(1H, d, J=8.5 Hz), 7.892(1H, d, J=2.1 Hz), 7.756(1H, br, J=2.1 Hz), 7.615(1H, d, J=1.0 Hz), 7.447(1H, dd, J=8.8, 2.5 Hz), 7.434(1H, s), 7.243(1H, dd, J=8.7, 1.7 Hz), 7.181(1H, m), and 7.160(1H, m); 13 C NMR(acetone-d 6 ) δ144.41(s), 138.65(s), 137.67(s), 126.38(s), 125.44(s), 123.82(d), 123.34(d), 123.09(d), 122.91(d), 122.72(d), 122.32(d), 120.70(d), 115.40(s), 115.15(d), 112.30(d), and 109.13(s); 1 H NMR(methanol-d 4 ) δ8.208(1H, m), 7.754(1H, s), 7.747(1H, d, J=8.4 Hz), 7.637(1H, s), 7.549(1H, d, J=1.6 Hz), 7.405(1H, m), 7.330(1H, s), 7.218(1H, dd, J=8.6, 1.7 Hz), 7.194(1H, m), and 7.169(1H, m); 13 C NMR(methanol-d 4 ) δ145.01(s), 138.86(s), 137.91(s), 132.65(s, br), 126.20(s), 125.38(s), 124.98(d), 123.58(d×2), 123.25(d), 121.16(d), 121.06(d), 117.25(d, br), 116.15(s), 115.27(d), 112.54(d), 110.18(s), and 108.10(s).
EXAMPLE 5--NORTOPSENTIN D
The derivative designated nortopsentin D has the structure shown in FIG. 1 wherein X1 is H and X2 is H. This compound can be readily prepared from nortopsentin A, B, or C by catalytic hydrogenation at room temperature and atmospheric pressure.
EXAMPLE 6--PREPARATION OF TRIMETHYL--AND TETRAMETHYLNORTOPSENTIN B
Nortopsentin B (23.0 mg) was treated with dimethyl sulfate (1.0 ml) and K 2 CO 3 (30 mg) in dry acetone at room temperature for 16 hours. The reaction mixture was filtered and separated on silica TLC plates (Kieselgel 60F 254 , 1 mm thickness, 5:1 chloroform/methanol) to afford 8.5 mg of trimethylnortopsentin B and 19.7 mg of tetramethylnortopsentin B as methyl sulfate salts. Their chloride salts were prepared by passing through a strong anion exchange column (Baker, Solid Phase Extraction Column, Quaternary amine, Cl - form) with 1:1 methanol/water.
Trimethylnortopsentin B (MeSO 4 - salt), colorless crystals, crystallized from chloroform/ethyl acetate; mp. 116°-118° C.; HREIMS m/z 404.0631(calcd. for C 21 H 17 N 4 Br=M + +H--CH 3 , Δ0.6 mmu); LREIMS m/z 419.9(0.5), 417.9(0.5), 405.9(3.7), 403.9(3.8), 280.9(2.6), 207.0(25.0), 190.9(3.6), 169.0(2.6), 155.0(1.9), 141.9(5.0), 133.0(4.0), 96.0(27.3), 94.0(28.6), 82.0(14.1), 79.8(15.1), 64.0(49.2), and 44.1(100.0 rel %); UV(Cl - salt, MeOH) λmax 200.0(ε37,800), 217.5(ε48,200), 272(sh), 280(ε20.700), 287.5(ε21,100), 293.5(ε19,300), and 314(sh) nm; IR(Cl - salt, KBr) 3400, 1625, 1615(sh), 1580, 1561, 1525, 1495(br), 1450, 1420(sh), 1363, 1340, 1322, 1296, 1245, 1228, 1185, 1157, 1137, 1105, 1053, 1013, 978, 944, 811, and 750 cm -1 ; 1 H NMR(MeSO 4 - salt, acetone, d b ) δ11.416(1H, br), 8.276(1H, s), 7.944(1H, s), 7.919(1H, d, J=1.7 Hz), 7.879(1H, d, J=2.8 Hz), 7.734(1H, brd, J=7.8 Hz), 7.666(1H, d, J=8.5 Hz), 7.630(1H, brd, J=8.0 Hz), 7.411(1H, dd, J=8.4, 1.7 Hz), 7.233(1H, ddd, J=8.3, 7.0, 1.3 Hz), 7.161(1H, ddd, J=8.3, 7.0, 1.3 Hz), 4.081(1H, s), 3.809(3H, s), and 3.516(3H, s); 13 C NMR(MeSO 4 - salt, acetone, d b ) δ142.08(s), 138.97(s), 137.53(s), 136.21(d), 131.05(s), 127.95(d), 126.99(s), 126.09(s), 125.60(d), 123.39(d), 121.90(d), 121.38(d×2), 119.52(d), 117.11(s), 115.03(d), 113.37(d), 101.19(s), 96.07(s), 53.61(l), 36.39(q), 35.07(q), and 34.07(q).
Tetramethylnortopsentin B (MeSO 4 - salt), colorless needles, recrystallized from chloroform/ethyl acetate in a freezer; MP 155°-165° C.; HREIMS m/z 418.0786 (calcd. for C 22 H 19 N 4 Br=M + +H--CH 3 , Δ0.8 mmu); LREIMS m/z 420.0(100.0), 418.3(98.7), 405.0(13.9), 403.0(13.9), 340.0(12.0), 209.9(19.8), 208.9(21.1), 183.0(27.0), 169.0(24.4), 162.0(7.9), 156.0(10.1), 148.5(11.7), 142.0(19.0), 128.0(7.4), 115.1(14.2), 101.0(5.6), 82.0(14.1), 79.8(15.4), 52.0(22.9), and 49.8(68.5 rel. %); UV(Cl - salt, MeOH) λmax 199.0(ε37,100), 220.5(ε48,300), 268(sh), 286.5(ε20,300), 294.0(ε20,800), and 312(sh) nm; IR(Cl - salt, KBr), 1624, 1610(sh), 1578, 1560, 1527, 1500, 1464, 1450(sh), 1420, 1363, 1334, 1296, 1250, 1225, 1189, 1159, 1133, 1103(sh), 1094, 1051, 1013, 965, 935, 810, and 746 cm -1 ; 1 H NMR(MeSO 4 - salt, chloroform-d) δ8.731(1H, s), 7.673(1H, s), 7.630(1H, d, J=1.7 Hz), 7.607(1H, brd, J=7.4 Hz), 7.374(1H, dd, J=8.5, 1.7 Hz), 7.299(1H, ddd, J=8.1, 7.0, 1.1 Hz), 7.270(1H, d, J=8.5 Hz), 7.215(1H, ddd, J=8.1, 6.9, 1.2 Hz), 3.954(3H, s), 3.861(3H, s), 3.836(3H, s), 3.717(3H, s), and 3.680(3H, s); 13 C NMR(MeSO 4 - salt, chloroform-d) δ141.49(s), 137.85(s), 136.86(s), 136.40(d), 131.14(d), 130.13(s), 126.57(s), 125.26(d), 124.66(s), 122.86(d), 121.09(d), 120.34(d), 119.73(d), 118.79(d), 116.86(s), 114.09(d), 110.12(d), 99.05(s), 94.47(s), 54.27(q), 36.25(q), 34.78(q), 33.80(q), and 33.22(q).
EXAMPLE 7--P388 IN VITRO ANTITUMOR SCREEN
Cell culture.
P388 murine leukemia cells, obtained from the National Cancer Institute, Bethesda, MD, were maintained at 37° C. in 5% CO 2 in humidified air. Growth medium was Roswell Park Memorial Institute medium 1640 supplemented with 10% heat-inactivated horse serum. Stock cultures of P388 cells were grown in antibiotic-free growth medium and were subcultured (10 5 cells/ml, 25 ml cultures in T-25 plastic tissue culture flasks) every 2-3 days. Every 3-4 months, stock cultures were re-initiated from frozen cells that were demonstrated to be free of mycoplasma contamination. To determine if organisms possess compounds having activity against P388 cells, extracts were diluted in methanol and added to cultures of P388 cells. An appropriate volume of the dilution was transferred to duplicate wells in a 96-well plate, evaporated to dryness, and 200 μl of growth medium-containing cells at a density of 1×10 5 cells/ml were added per well (final concentration of extract was 20 μg/ml). Each plate included six wells containing untreated cells for control growth (mean generation time was 15.2±0.7 hour, n=26 separate determinations) and replicate wells containing fluorouracil (0.2 μg/ml, ca. 95% inhibition of cell replication) as a positive control. For daily quality control, each technician determines the IC 50 of fluorouracil for inhibition of P388 cell proliferation. After 48-hour incubations, cell number was determined with the MTT assay (below), calculated as a percent of untreated cell growth, converted to percent inhibition, and reported to the chemist requesting the screen.
Determination of IC 50 values.
The initial determination of an IC 50 value for inhibition of P388 cell proliferation with a crude, semipure, or pure sample was made by diluting the sample in methanol to the appropriate concentration, and then serial 1:1 dilutions were made in duplicate in a 96-well plate, such that the final concentrations in the assay were 20, 10, 5, 1.25, and 0.625 μg/ml. After solvent was evaporated to dryness, cells were added to each well as described above. After 48-hour incubations, cell numbers were determined with the MTT assay, converted to percent control, and plotted versus the log of the sample concentration. Curves were fitted by least-squares linear regression of logit-transformed data and the concentration of sample that inhibited cell proliferation by 50% was reported to the chemist requesting the screen. If the IC 50 value was less than 0.625 μg/ml, additional serial dilutions were made and tested for activity.
MTT assay for cell number.
MTT or 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyl-tetrazolium bromide is used in an established method (J. Immunol. Methods [1983] 65:55-63) to enumerate cells rather than "Coulter counting." For screening purposes, the correlation between percent inhibition determined for actual crude extracts with the Coulter counter and MTT method was very good (r=0.953, n=102 separate determinations of activity at 20 μg/ml), and no extract that was positive as determined by actual cell counts was lost using the MTT assay. Additional results indicated that the MTT assay yielded very similar values for IC 50 's in parallel determination with Coulter counting. The results of the P388 assay are shown in Table 1.
TABLE 1______________________________________ Antitumor P388Sample IC.sub.50, μg/ml______________________________________Nortopsentin A 7.6Nortopsentin B 7.8Nortopsentin C 1.7Trimethylnortopsentin B 0.9(chloride salt)Tetramethylnortopsentin B 0.34______________________________________
As can be seen from Table 1, each of the compounds tested showed antitumor activity.
ANTIMICROBIAL PROTOCOLS
Preparation of inocula.
Unless otherwise noted, all media were autoclaved at 121° C. for 15 minutes.
Candida albicans: C. albicans (ATCC strain 44506 was grown on Sabouraud dextrose agar to produce single colonies, one of which was used to inoculate Sabouraud dextrose broth. The broth was incubated at 37° C. with shaking at 200 rpm for 18 hours. The resultant culture was brought to 10% (v/v) glycerol, frozen at -80° C., and used as the inoculum for the anti-Candida assay.
Bacillus subtilis:
Standard spore stocks (ATCC strain 6633 were purchased from Difco (#0453-36-0).
Assay protocols.
1. Disc diffusion assay
C. albicans was inoculated into either melted Sabourand dextrose agar or RPMI-1640 in 2% agar at 45° C. to give a cell density of approximately 10,000 cells/mL. Plates were prepared with 10 mL of the seeded agar in a 10 cm×10 cm petri dish. These plates were stored at 4° C. until needed for the assay.
B. subtilis was inoculated into Penassay medium (1 mL of stock per 200 mL agar), melted, and cooled to 45° C. Plates were poured as described above.
Paper discs (6.35 mm) were impregnated with the test substance and allowed to dry. They were then placed onto the surface of a test plate prepared as detailed above. Plates were incubated overnight at 37° C., after which time the zones of growh inhibition could be read. These were expressed as the diameter of the zone in millimeters. Standard drugs were used in all cases.
2. MIC protocol
Two-fold dilutions of the test compound were prepared in 50 μL volumes of a suitable solvent using 96-well microtiter plates. In a separate 96-well plate, 35 μL volumes of either Sabouraud dextrose broth or RPMI-1640 were placed in each well. The test compound (5 μL) was then transferred to the broth. An inoculum of C. albicans in the appropriate medium was added to give a cell density of 1000 cells/mL and a total volume of 50 μL. Plates were incubated at 37° C. overnight. 10 μL of triphenyl tetrazolium chloride (1 w/v; filter sterilized) was then added to each well; a further 2-hour incubation resulted in a deep coloration of the microorganism. The MIC is the lowest concentration of the drug which completely inhibited growth.
TABLE 2______________________________________ Antimicrobial Bacillus subtilis Candida albicans zone (20 μg/disc) MIC, μg/ml______________________________________Nortopsentin A 8 3.1Nortopsentin B 9 6.2Nortopsentin C 9 12.5Trimethylnortopsentin B 11 >50.0(chloride salt)Tetramethlynortopsentin B 12 >50.0______________________________________
As can be seen in Table 2, the novel compounds showed activity against microbes.
The compounds of the invention are useful for various non-therapeutic and therapeutic purposes. It is apparent from the testing the the compounds of the invention are effective for inhibiting microbial growth and for controlling microbial diseases. Also, because of the antimicrobial properties of the compounds, they are useful to swab laboratory benches and equipment in a microbiology laboratory to eliminate the presence of microbes, or they can be used as ultraviolet screeners in the plastics industry since they effectively absorb UV rays. As disclosed herein, they are also useful prophylactically and therapeutically for treating microbial infections in animals and humans.
Therapeutic application of the new compounds and compositions containing them can be contemplated to be accomplished by any suitable therapeutic method and technique presently or prospectively known to those skilled in the art. Further, the compounds of the invention have use as starting materials or intermediates for the preparation of other useful compounds and compositions.
The dosage administration to a host in the above indications will be dependent upon the identity of the infection, the type of host involved, its age, health, weight, kind of concurrent treatment, if any, frequency of treatment, and therapeutic ratio.
The compounds of the subject invention can be formulated according to known methods for preparing pharmaceutically useful compositions. Formulations are described in detail in a number of sources which are well known and readily available to those skilled in the art. For example, Remington's Pharmaceutical Science by E. W. Martin describes formulations which can be used in connection with the subject invention. In general, the compositions of the subject invention will be formulated such that an effective amount of the bioactive compound(s) is combined with a suitable carrier in order to facilitate effective administration of the composition. | Novel brominated bisindole-imidazole alkaloids have been isolated from marine sponges. These compounds, and derivatives thereof, are useful antimicrobial and antitumor compounds. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of U.S. patent application Ser. No. 12/523,253 filed Sep. 8, 2009 which was a U.S. National Phase entry of PCT/NL2008/000014 filed Jan. 11, 2008, and claims priority from Netherlands patent application 1033228 filed Jan. 15, 2007, and Netherlands patent application 1034160 filed Jul. 19, 2007.
BACKGROUND OF THE INVENTION
The present invention relates to the use in a liquid fuel composition comprising a mixture of hydrocarbons of at least a compound that suppresses the emission of soot particulates. The present invention also relates to a method for reducing the emission of soot particulates in the exhaust gases of an internal combustion engine, and to such a liquid fuel composition.
Known from U.S. Pat. No. 4,378,973 is a diesel fuel composition in which, in order to reduce the emission of soot particulates, is incorporated a mixture of cyclohexane with at least one oxygenated compound, the amount of cyclohexane amounting to 0.5-5.0 wt. % and the amount of oxygenated compound to between 0.5 and 5.0 wt. %. Mentioned as examples of suitable oxygenated compounds are isobutyl heptyl ketone, acetone, tetrahydrofuran, 1,2-butylene oxide, dimethyl ether, propionaldehyde, ethanol, 2-ethylhexanol or a mixture of primary alcohols containing between 6 and 20 carbon atoms. The explanation provided in the aforementioned US patent is that the oxygenated compounds burn cleaner than the hydrocarbon fuel, as a result of which the particulates formed in the combustion will be smaller and more polar than the particulates obtained in the combustion of the hydrocarbon fuel itself. It is subsequently assumed that the attachment of such a polar particulate to a particulate formed in the combustion of the hydrocarbon fuel will yield a polar particulate that will tend to resist conglomeration with larger particulates, the result of which will be downsizing of the average particulate size of the soot particulates. Cyclohexane is volatile and rich in hydrogen atoms, which, it is claimed, will ensure early, steady combustion of the fuel composition during injection of the fuel. It is claimed that the combination of the early, steady combustion effected by cyclohexane and the polarisation of the particulates by the oxygen-rich additives in a synergistic manner effects a reduction in particulates.
U.S. Pat. Nos. 6,458,176, 6,447,557 and 6,447,558 disclose a diesel fuel composition in which, in order to reduce the emission of soot particulates, is incorporated an oxygenated compound in an amount such that a minimum percentage by weight of oxygen is added to the overall fuel composition, in particular at least 2.0 wt. % oxygen. Mentioned as examples of suitable oxygenated compounds are inter alia saturated aliphatic monovalent primary, secondary or tertiary alcohols with an average of 9-20 carbon atoms, such as octanol, hexanone, nonanol, stearyl alcohol, in particular ketone compounds containing 5-21 carbon atoms. It is assumed that the emission of soot particulates is caused by incomplete combustion of the fuel, and the aim is therefore to increase the oxygen value of the fuel to facilitate the combustion. The aforementioned three US patents disclose experimental data relating to isodecanol, isononanol, dimethyl heptanol, dimethyl octanol and dimethyl heptanone, which experimental results indicated that the aforementioned secondary and tertiary alcohols and ketone show a reduction in the emission of soot particulates corresponding to that of a primary alcohol compound.
JP 07 331262 relates to a fuel composition for a diesel engine that is capable of reducing particulate substances contained in the black smoke emitted to the atmosphere, which composition comprises an oxygenated compound such as a derivative of a carboxylic ester, a glycol ether or glycol ester or an oxygenated heterocyclic compound, the cyclic compound's ring structure consisting of four carbon atoms and two oxygen atoms, the oxygen atoms being separated from one another by one or two carbon atoms.
U.S. Pat. No. 3,594,138 relates to a liquid fuel composition comprising a Group II-A metal salt of an alkanoic acid and an alkyl ether of glycol with 3 to 10 carbon atoms, which metal salt is present in an amount of about 0.01 to 2 wt. %, relative to the total weight of the fuel mixture. Barium, strontium and calcium are mentioned as suitable metals.
U.S. Pat. No. 5,931,977 relates to a compound intended for use as an additive for a diesel fuel, the additive containing 30-55% alcohol, 25-35% ketone compounds and 3-10% silicon compounds, the alcohol consisting of methanol, n-butanol and benzyl alcohol, and the ketone compound being 20-25% cyclohexanone and 6-10% methyl ethyl ketone.
Korean patent application KR 100 321 477 relates to a fuel composition that contains 1,3-dioxane derivatives for the purpose of the removal of particulates emitted by a diesel engine. The dioxane compounds mentioned in the aforementioned Korean publication can be described as cyclic hexagonal compounds, with the ring structure containing two oxygen atoms and four carbon atoms.
European patent application EP 1 321 502 relates to a diesel fuel composition that contains an additive, notably at least a glycerol acetal, the acetal compounds being characterised by a cyclic compound consisting of five atoms, with the ring structure of the cyclic compound containing two oxygen atoms in addition to three carbon atoms, or a cyclic compound consisting of six atoms, with the ring structure of the cyclic compound containing four carbon atoms in addition to two oxygen atoms.
European patent application EP 1 188 812 relates to a diesel fuel that contains a tetrahydrofurfuryl derivative that is characterised by a cyclic compound whose ring structure contains an oxygen atom in addition to four carbon atoms. The aforementioned compound must also contain a branch, with a carbon atom of the ring being directly bound to a carbon atom that is bound to an oxygen atom to which is attached an alkyl group, which alkyl group may also contain an oxygen atom.
Known from International application WO 01/18155 is a fuel composition, between 5 and 100% of which consists of a group of nine oxygen-containing organic compounds, which fuel composition must always contain at least four different oxygen-containing functional groups chosen from the aforementioned group of nine members, which groups must be divided between at least two different oxygen-containing compounds. The examples disclosed in this document show predominantly aliphatic hydrocarbon compounds, with a ring structure consisting of four carbon atoms being used only in, inter alia, examples 2, 5, 12, 14 and 15.
European patent application EP 0 905 217 relates to an unleaded gasoline for a gasoline engine that contains an oxygen-containing compound with 2-15 carbon atoms, with butyl lactone being mentioned as the oxygen-containing compound.
International application WO 95/20637 relates to a very broad, generally defined hydrocarbon composition, but it is not unambiguously specified what compounds are to be regarded as essential components.
International application WO 01/53437 relates to a method of reducing the vapour pressure of a fuel mixture for spark-ignition engines, notably gasoline engines, according to which an oxygen-containing compound is added to the fuel in an amount of at least 0.05 vol. % of the total fuel mixture.
The diesel fuel commonly used for transport purposes is a mixture consisting of predominantly, i.e. approximately 75 wt. %, saturated hydrocarbon compounds, the key constituent of which consists of n-paraffins. The term ‘saturated’ used in this context refers to the maximum number of hydrogen atoms for a specific carbon skeleton. In other words, a saturated hydrocarbon compound is characterised by the absence of double or multiple carbon-carbon bonds. Naphthene and also iso-paraffins, the remaining saturated compounds, and also olefins are moreover found in diesel fuels in only sporadic quantities. Aromatic compounds in which single ring bonds prevail over aromatic compounds consisting of several rings constitute the remaining 25 wt. %.
The emission of soot particulates formed in the combustion of fuels in a fuel engine is considered undesirable. These particulates are regarded as harmful substances. European legislation demands the reduction of the emission of soot particulates in the coming years.
The aim of the present invention is therefore to provide a liquid fuel composition that suppresses the soot-formation process during its use, and consequently emits a reduced quantity of particulate combustion products.
Another aim of the present invention is to provide a liquid fuel composition that shows a reduced emission of soot particulates without the performance of the fuel engine being adversely affected.
Yet another aim of the present invention is to provide a liquid fuel composition which, if used in a fuel engine, does not cause undesired wear of the engine parts.
Another aim of the present invention is to provide a liquid fuel composition that suppresses the emission of soot, in particular in a diesel engine, with EGR (exhaust gas recycling) taking place to suppress the emission of NOx, with it being in particular desirable to simultaneously suppress the emission of soot and the emission of NOx.
The present invention is characterised in that the compound is a cyclic hydrocarbon compound whose ring contains at least five carbon atoms, which compound contains at least an oxygen atom.
One or more of the aforementioned aims can be met by using such a liquid fuel composition. In a particular embodiment of the present invention it is desirable for the cyclic hydrocarbon compound to have one or more branches, which branches may optionally be an aliphatic hydrocarbon group and may optionally be cyclic, or a combination of the two. The number of at least 5 carbon atoms in the ring structure is desired to guarantee the compound's stability, with the volatility of the cyclic hydrocarbon compound also playing a role, in particular from the viewpoint of the user's safety. A quantity of at most 20 carbon atoms in the ring structure is preferable from the viewpoint of the solubility of the cyclic hydrocarbon compound in the intended fuel. The present cyclic hydrocarbon compound must moreover be seen as a compound that consists exclusively of a combination of C, H, O atoms, with there being no question of the cyclic hydrocarbon compound containing one or more of the group comprising metals, silicon, phosphorus and nitrogen atoms. The bond between the carbon atoms in the ring may be single, double or aromatic. When the ring contains at least an oxygen atom, the bond between the oxygen and the adjacent carbon will be single. The ring may have one or more branches, which branches may contain one or more oxygen atoms. A branch without oxygen atoms is also possible. The structure of the branch is linear, branched or cyclic, or a combination thereof. If the oxygen atom is outside the ring, the bond between the oxygen and the carbon may be either single, as in for example cyclohexanol, or double, as in for example cyclohexanone.
A particularly favourable compound that suppresses the emission of soot particulates is a cyclic hydrocarbon compound that contains one or more oxygen atoms, the one or more oxygen atoms in particular being contained outside the ring.
The quantity of cyclic hydrocarbon compound contained in the liquid fuel composition is at least 5 wt. %, preferably at least 10 wt. %, in particular at least 30 wt. %, relative to the total weight of the liquid fuel composition.
The present inventor has discovered that cyclohexanone is a particularly good compound that suppresses the emission of soot particulates and moreover prevents the formation of NOx.
In addition to cyclohexanone and cyclopentanol, the following can be mentioned as suitable compounds that meet one or more of the aims of the present invention: tetrahydropyran, cyclohexanol, cyclohexenol, phenol, cyclohexyl methanol, anisole, methoxycyclopentane, 3,5-dimethyl cyclohexanol, 2-isopropyl cyclohexanol and dicyclohexyl ether.
The present liquid fuel composition is more or less organic in nature and the cyclic hydrocarbon compound does not require the presence of metal salts such as barium, strontium and calcium to ensure a good performance, as disclosed in U.S. Pat. No. 3,594,138. Any salts present are to be regarded as unavoidable impurities deriving from the starting materials and will in certain embodiments amount to at most 0.01 wt. %, in particular at most 0.005 wt. %, relative to the weight of the total liquid fuel composition.
The present liquid fuel composition is further characterised in that the concentration of silicon compounds in the liquid fuel composition is at most 3%; silicon oil, ethyl silicate and combinations thereof can be quoted as examples.
The present cyclic hydrocarbon compound suppressing the emission of soot particulates must be soluble in the liquid fuel composition. It is also desirable for the cyclic hydrocarbon compound to show boiling behaviour that is comparable with that of the fuel composition in which the compound is dissolved. The following can be mentioned as suitable liquid fuel compositions in which the present cyclic hydrocarbon compound can be used: diesel fuel, jet fuel, kerosine, gasoline, bunker fuel and mixtures hereof. Synthetic or Fischer-Tropsch fuels can also be mentioned as liquid fuel compositions, and also vegetable oils and so-termed biofuels.
The liquid fuel composition according to the present invention may contain one or more of the usual additives, such as agents affecting flow at low temperatures, agents suppressing the precipitation of waxy components, stabilisers, antioxidants, agents for improving the cetane number, agents for promoting combustion, detergents, defoaming agents, lubricants, antifoaming agents, antistatic agents, agents for promoting conductivity, corrosion-suppressing agents, fragrances, pigments, friction-reducing agents and the like.
In addition to the aforementioned compounds the liquid fuel composition may also contain the usual agents commercially employed for suppressing the emission of soot particulates, notably so-termed oxygen-containing compounds, also known as oxygenates. The additives commonly used to reduce the emission of nitrogen oxides may also be used in the present liquid fuel composition.
In particular, the present invention focuses on the use of the present cyclic hydrocarbon compound in so-termed compression-ignition (CI) engines, in particular diesel engines, as opposed to so-termed spark-ignition (SI) engines, in particular gasoline engines, for which the present cyclic hydrocarbon compound is unsuitable.
Intensive research has shown that it is possible to reduce the concentration of soot particulates in off-gas without the concentration of nitrogen oxides in the off-gas being increased or even being lowered, it being preferable for the liquid fuel composition to have a cetane number of 10-40, in particular 15-35.
The cetane number is a value indicating a fuel's knocking tendency, usually for a diesel engine, but said cetane number also holds for other fuels and has a function like the octane number in the case of gasoline. The cetane number of cetane is 100 and the cetane number of α-methylnaphthalene is 0. A mixture of the two components has a cetane number corresponding to the volume percentage of cetane in the mixture. The cetane number of the most commonly used diesel fuel mixtures is between 44.2 and 51.8. At a cetane number of less than 10 the self-ignition time is delayed too much. The cetane number of gasoline fuel mixed with ethanol is usually negative or about 0. Substances are often added to the base fuel to increase the cetane number so as to arrive at faster combustion. On the basis of what has now been discovered it has however been decided to ensure that the cetane number remains below 40. The cetane number (CN) characterises a fuel's self-ignition behaviour. A lower CN value corresponds to a lower fuel reactivity and a longer ignition delay. The cetane numbers of tripropylene glycol monomethyl ether and di-n-butyl maleate (TP and DB) are 75 and 30, respectively. The cetane number of cyclohexanone is about 16. In order to reduce the cetane number of the fuel mixture to below 40 it is hence preferable to use an oxygen compound of a cyclic hydrocarbon. When use is made of an oxygen compound of a non-cyclic hydrocarbon the cetane number can be reduced to below 40 by adding substances known per se that have a cetane number such that the value of the overall fuel mixture drops to below 40.
The inventor found that at 25% exhaust gas recirculation (EGR) the emission of soot particulates at a cetane number of 34.6 was substantially lower than at cetane numbers of 46.3 and 53.9, and that the concentration of nitrogen oxides was at the same time also lower (employed engine: DAF 9.2 liters (heavy-duty diesel engine) at 25% EGR without after-treatment, determined relative to EURO V (European emission standard as at 10-2008 for “heavy-duty diesel vehicles”).
Particular embodiments of the present liquid fuel composition are represented in the included claims. The present invention will be illustrated with reference to a number of examples below, to which it should however be added that the present invention is by no means restricted to such particular examples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the effect of exhaust gas recirculation (EGR) and cyclohexanone content on NOx emission and the degree or intensity of the soot.
FIG. 2 shows the behaviour of cyclohexanone in relation to a number of commercially available oxygen-containing compounds that are commonly used to reduce the emission of soot particulates, which oxygen-containing compounds do not have a cyclic structure.
DESCRIPTION OF THE INVENTION
Three additives were investigated and each was mixed with a commercially available diesel fuel, notably EN590 diesel with a low sulphur content, in order to obtain 9 wt. % oxygen in each fuel mixture ultimately obtained, which ratio holds for FIG. 2 . In this way three mixtures were obtained, each containing a different additive, the mixtures ultimately obtained being comparable because they all corresponded to 9 wt. % oxygen. The aforementioned ratio was chosen because that value corresponds to a mixture of diesel fuel and cyclohexanone that contains 9 wt. % oxygen, so that the performance could be compared with that of two “standard” oxygen-containing additives commonly used to reduce the emission of soot particulates, notably TPGME (tripropylene glycol monomethyl ether) and DBM (dibutyl maleate). The following measurements were carried out to measure the emission values, in particular NOx, HC, CO and soot: chemiluminescence (CL), flame ionisation detection (FID), non-dispersive infrared (NDIR) detection and filter smoke number (FSN) measurement. The particulate emission was inferred from the smoke values. The engine used for the tests was a DAF PE235C 4V engine; the experiments were carried out at a partial-load working point characteristic of a vehicle speed of about 80 km/hour.
FIG. 1 represents the effect of exhaust gas recirculation (EGR) and cyclohexanone concentration on the NOx emission (represented along the Y axis) and the degree or intensity of the soot (represented along the X axis). The dotted lines represent constant wt. % EGR. The curves represented as solid lines relate to vol. % cyclohexane. From this FIG. 1 it follows that the mixture of diesel fuel and cyclohexanone led to higher NOx values than the diesel fuel without cyclohexanone, notably zero volume % CHO.
The present inventor assumes that this behaviour is attributable to longer ignition delays, faster combustion and finally higher peak flame temperatures. The present inventor also assumes that the degree of NOx formation approximately increases exponentially with the flame temperature. The figure also indicates the European emission targets for NOx, notably EURO III, EURO IV and EURO V. Depending on the chosen cyclohexanone concentration it is clear that the NOx target of type EURO V is achieved when the employed EGR value is in the range of 17.5-22.5 wt. %. From this it consequently follows that EGR is a good way of reducing NOx emissions. The addition of cyclohexanone appears to substantially reduce the disadvantage of greatly increased soot emission occurring in EGR, because no increased soot emission is observed in the case of cyclohexanone at the same oxygen concentration. So the addition of cyclohexanone makes it possible to bring the emission of NOx within the EURO V range by means of EGR without there being any question of increased soot emission. This favourable effect is not observed in the case of the commonly used agents TPGME and DBM.
FIG. 2 shows the behaviour of cyclohexanone in comparison with that of the commercially available oxygen-containing compounds that are commonly used to reduce the emission of soot particulates The oxygen concentration in the liquid fuel composition was chosen to be constant in the mixtures of cyclohexanone (CHO), dibutyl maleate (DBM) and tripropylene glycol monomethylether (TPGME); in particular, the oxygen concentration was 9%, based on weight. The dotted lines in FIG. 2 represent constant wt. % EGR. The curves represented as solid lines relate to the different fuels. A clear positive influence on the emission of soot is observed even at lower oxygen concentrations (see FIG. 1 ). The emission or concentration of soot particulates in exhaust gas, also referred to as PM emission, as measured is expressed in the blackness of the exhaust gas in a range of 0-10, with 0 corresponding to an emission of no particulates and 10 corresponding to black smoke. It should be added that the commonly used oxygen-containing compounds DBM and TPGME are in the literature often referred to as compounds that show particularly good behaviour in the field of the reduction of the emission of soot particulates.
The present inventor attributes the behaviour of cyclohexanone with respect to reducing the emission of soot particulates, which behaviour is superior to the behaviour of DBM and TPGME, as can be seen in FIG. 2 , to the ignition behaviour of the fuels. The present inventor is however by no means bound to such an explanation. The soot-formation process that is responsible for soot emission is strongly opposed when the air and fuel are better mixed. The ignition delay, which is the time between the beginning of the injection process and the moment of self-ignition, of the mixture to be formed is lengthened due to the cyclic character of the present cyclic hydrocarbon compound. As a result, more time becomes available for the mixing process and the oxygen concentration in the soot-synthesis zone will in all probability be higher than in the case of mixtures with a shorter ignition delay, such as mixtures based on DBM and TPGME.
A possible explanation for the use of cyclohexanone is the assumption that, if incorporated in the predominantly hexagonal structure of soot precursors (polyaromatic hydrocarbons, PAHs), cyclic hydrocarbons with five (or to a lesser degree seven) carbon atoms, notably pentagons and septagons, respectively, will cause curvature. With the PAHs consequently being curved, the transition to soot crystals (stacked PAH plates) will proceed less readily. It is assumed that pyrolysis causes cyclohexanone to (partly) decompose into inter alia the aforementioned pentagons. Cyclic hydrocarbons tend to remain cyclic; so even larger molecules such as octagons will in part form the desired pentagons. A hexagonal hydrocarbon compound such as cyclohexanone is preferable from an economic perspective because hexagonal hydrocarbons (though without oxygen bonds) are already present in large quantities in crude oil and also have the most stable configuration. The present inventor is however by no means bound to such an explanation. | The present invention relates to a liquid fuel composition comprising a mixture of hydrocarbons and a cyclic hydrocarbon compound that suppresses the emission of soot particulates. The present invention also relates to a method for reducing the emission of soot particulates in the exhaust gases of an internal combustion engine. It is desirable for the cyclic hydrocarbon compound to contain one or more oxygen atoms. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to an integrated circuit and a layout method of a chip peripheral port on used in a layout system for supporting the design of the integrated circuit, more particularly, used for realizing the input/output function of an LSI (Large-Scale Integrated circuit).
FIG. 15 is a block diagram showing a main part of a layout system for a conventional integrated circuit.
A conventional layout system 60 includes an input/output block arranging means 61 for arranging input/output blocks at the peripheral portion of a chip, a macro-block arranging means 62 for arranging functional macro-blocks (to be referred to as macro-blocks hereinafter) in the inner region of the chip, and an interwiring means 65 for performing wiring between the macro-blocks and between the macro-blocks and the input/output blocks.
In an operation of the conventional layout system 60, as shown in FIG. 16, input/output block arranging processing is performed (step S31), macro-block arranging processing is performed (step S32), and finally, wiring processing between the macro-blocks and between the macro-blocks and the input/output blocks (step S33).
As described above, in an actual chip having the above layout, as shown in FIG. 17, macro-blocks 35 are arranged in the inner region of a semiconductor chip 1 (to be referred to as a chip hereinafter), input/output blocks 36 are arranged on each side of the chip peripheral portion, and corner blocks 37 serving as the input/output blocks are arranged at the four corners of the chip. In this case, each of the input/output blocks 36, as shown in FIG. 18, includes an input/output buffer (to be referred to as a buffer hereinafter) 38 and a bonding pad (to be referred to as a pad hereinafter) 39 connected to the buffer 38, and the buffer 38 includes power supply wiring patterns 40. As shown in FIG. 19, each of the corner blocks 37 includes power supply wiring patterns 41 for connecting the power supply wiring patterns 40 of the input/output blocks 36 positioned at both the sides of the corner block 37.
As shown in FIG. 20, the pad 39 included in each of the input/output blocks 36 must be arranged at a predetermined position so as to be connected to a lead frame 43 and a bonding line 42 when a chip of an LSI is assembled, and each of the input/output blocks 36 must be arranged at a position such that the pad 39 is kept at the predetermined position. Therefore, when a chip has a large number of pads, unless the input/output blocks 36 each have a sufficiently small width are equipped, the input/output blocks cannot be arranged to satisfy the above limitation. In addition, since the corner blocks 37 are arranged at the corner portions of the chip, the normal input/output blocks 36, i.e., the pads 39, cannot be arranged. For this reason, the regions of the corner portions cannot be effectively utilized.
As described above, in each chip of an LSI laid out by a conventional layout system, especially in the peripheral portion of the chip, there are large waste regions such as intervals between input/output blocks and unused regions of the corner portions. Especially in a chip having a large number of pads, regions for positioning pads are short.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an integrated circuit capable of effectively utilizing the region of a semiconductor chip peripheral portion and a layout system for the integrated circuit.
It is another object of the present invention to provide an integrated circuit capable of decreasing the area of a semiconductor chip and a layout system for the integrated circuit.
In order to achieve the above object, according to an aspect of the present invention, there is provided an integrated circuit comprising a plurality of macro-blocks arranged in an inner region of a semiconductor chip, a plurality of input/output blocks arranged at a peripheral portion of the functional macro-blocks, bonding pads respectively arranged between the input/output blocks and an outer frame of the semiconductor chip, a first layout obtained by performing predetermined wiring between the macro-blocks and between the macro-blocks and the input/output blocks, and a second layout obtained by performing wiring between the input/output blocks and the corresponding bonding pads.
In order to achieve the above objects, according to another aspect of the present invention, there is provided a layout system for an integrated circuit, comprising input/output block arranging means for initially arranging a plurality of input/output blocks at a peripheral portion of a semiconductor chip, separating bonding pads from the input/output blocks, and arranging the separated bonding pads between the input/output blocks and an outer frame of the semiconductor chip, functional macro-block arranging means for arranging a plurality of functional macro-blocks in an inner region of the semiconductor chip, interwiring means for performing wiring between the bonding pads and the corresponding input/output blocks, and interwiring means for performing predetermined wiring between the functional macro-blocks and between the functional macro-blocks and the input/output blocks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are layout views showing an integrated circuit according to an embodiment of the present invention;
FIG. 2 is a block diagram showing a main part of a layout system according to an embodiment of the present invention;
FIG. 3 is a view for explaining an input/output environment of the layout system in FIG. 2;
FIG. 4 is a flow chart showing an overall operation of the layout system;
FIG. 5 is a flow chart showing interwiring processing between an input/output block and a pad by the layout system;
FIG. 6 is a layout view showing input/output block arranging processing of the layout system in detail;
FIG. 7 is a layout view showing macro-block arranging processing of the layout system in detail;
FIG. 8 is a layout view showing input/output block arrangement improving processing of the layout system in detail;
FIG. 9 is a layout view showing wiring processing of the layout system;
FIG. 10 is a layout view showing terminal setting processing of the layout system;
FIG. 11 is a view for explaining another input environment of the layout system according to an embodiment of the present invention;
FIG. 12 is a flow chart showing wiring processing between an input block and a pad;
FIG. 13 is a layout view showing a wiring improving processing of the layout system in detail;
FIG. 14 is a layout view showing a wiring improving processing of the layout system in detail;
FIG. 15 is a block diagram showing a main part of a conventional layout system;
FIG. 16 is a flow chart showing an operation of the layout system shown in FIG. 15;
FIG. 17 is a layout view showing a conventional integrated circuit;
FIG. 18 is a layout view showing an input/output block of the integrated circuit in FIG. 17;
FIG. 19 is a layout view showing a corner block of the integrated circuit in FIG. 17; and
FIG. 20 is a layout view for explaining a state wherein a chip is assembled.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be described below with reference to the accompanying drawings.
FIGS. 1A and 1B show a layout of an LSI according to an embodiment of the present invention. Note that FIG. 1B shows an enlarged portion of FIG. 1A.
An LSI according to this embodiment has a layout comprising macro-blocks 2 arranged in the inner region of a chip 1 and input/output blocks 3 including corner blocks 4 arranged around the macro-blocks 2. According tothe characteristic features of the present invention, the integrated circuit comprises a layout including pads 5 arranged between the input/output blocks 3, the corner blocks 4, and the outer frame of the chip, e.g., on the outer frame of the chip, and wiring lines 6a for connecting terminals 8 of the pads 5a to terminals 7 of the input/output blocks 3a, wherein input/output blocks 3a have no pad.
FIG. 2 shows a main part of a layout system of an integrated circuit according to an embodiment of the present invention, and FIG. 3 shows an input/output environment of the layout system.
As shown in FIG. 3, according to this embodiment, a layout system 60a receives data from a design rule file 50, a underlying frame file 51, a pad assignment file 52, an input/output block library file 53, a macro-block library file 54, and circuit connection information 55, performs layout, and outputs an overall chip layout 56.
As shown in FIG. 2, a layout system according to this embodiment is a layout system 60a for an integrated circuit, comprising an input/output block arranging means 61 for arranging input/output blocks including corner blocks at the peripheral portion of a chip, a macro-block arrangingmeans 62 for arranging macro-blocks in the inner region of the chip, and aninterwiring means 65 for performing wiring between the macro-blocks and between the macro-blocks and the input/output blocks. According to the characteristic features of the present invention, the input/output block arranging means 61 includes a means for separating the input/output blocksfrom pads and arranging the separated pads between the input/output blocks and the outer frame of the chip and comprises an input/output block arrangement improving means 63 for improving the arrangement of the arranged input/output blocks on the basis of the connection relationship between the input/output blocks and the macro-blocks and an interwiring means 64 for performing wiring between the arranged bonding pads and the corresponding input/output blocks.
An operation of the layout system according to this embodiment will be described below with reference to FIGS. 3 to 10. FIG. 4 shows an overall operation of the layout system, FIG. 5 shows interwiring processing between an input/output block and a pad, and FIGS. 6 to 10 show processingoperations in detail.
In FIG. 4, an input/output block arranging processing of step S1, as shown in the input/output environment of FIG. 3, the underlying frame file 51 inwhich pad coordinates are described within a frame having a predetermined size, the pad assignment file 52 for assigning an input/output block to bedesignated to a specific pad, the input/output block library file 53, and the circuit connecting information 55 are loaded, and the input/output blocks are initially arranged. FIG. 6 shows a layout after the input/output blocks are arranged. Since specific input/output blocks 10 and 11 are designated to be respectively connected to pads 12 and 13 arranged on the outer frame of the chip 1 by the pad assignment file 52, the input/output blocks 10 and 11 are arranged at positions near the pads 12 and 13. Since other input/output blocks are not especially designated, the input/output blocks are arranged at positions corresponding to the remaining pads arranged on the outer frame of the chip 1.
In macro-block arranging processing of step S2, macro-blocks are arranged in a frame surrounded by the input/output blocks with reference to the macro-block library file 54. At this time, the arrangement positions of the macro-blocks are determined such that macro-blocks having a strong connection relationship are close to each other. FIG. 7 shows a layout after the macro-blocks are arranged, and the macro-blocks are arranged in a frame 14.
In input/output arrangement improving processing of step S3, the arrangement of the input/output blocks which have been initially arranged is improved with reference to connection relationships between the input/output blocks and the macro-blocks. FIG. 8 shows the arrangement improving processing. Since input/output blocks 15 and 16 have connection relationships with macro-blocks 18 and 17, respectively, the two input/output blocks 15 and 16 are replaced with each other, thereby improving the arrangement of the input/output blocks 15 and 16. At this time, the arrangement coordinates of the input/output blocks are determined, and simultaneously, the relationships between the input/outputblocks and the pads are determined.
In interwiring processing between an input/output block and a pad in step S4, a wiring line for connecting an input/output block to a pad corresponding to the input/output block is formed. FIG. 5 shows this wiring processing in detail. In wiring pattern determining processing of step S11, the shape of the wiring line and the drawing direction of the wiring line are determined by a positional relationship between the input/output blocks and the pads. FIG. 9 shows this determining processing. In FIG. 9, a wiring pattern is selected as follows. That is, since a pad 19 is positioned on the left side of a corresponding input/output block 21, the wiring pattern is drawn from the right direction of the pad 19, and the wiring pattern is bent in the upper direction and reaches the input/output block 21. In addition, since a pad 20 is positioned parallel to an input/output block 22, a pattern which is vertically drawn from the upper direction of the pad 20 and reaches the input/output block 22 is selected.
In terminal setting processing of step S12, terminals are set at wiring line drawing sides of the input/output blocks and the pads determined in step S11. At this time, design rules such as the width of a wiring line and a minimum wiring line interval are loaded from the design rule file 50. FIG. 10 shows a layout showing this processing. In FIG. 10, a pad 23 and an input/output block are not positioned on the same X-coordinate axis. Since a wiring line is drawn from the right side of the pad 23, a terminal 27 is set at a position lower than the upper right corner of the pad 23 by a half of a wiring width w/2. In an input/output block 25, a terminal 28 is set at a position shifted from the lower left corner of theblock 25 to the right direction by a half of the (wiring width w)+(minimum interwiring interval s). The lower left corner of the block 25 is the closest to the pad 23. On the other hand, since a pad 24 and an input/output block 26 are positioned on the same X-coordinate axis, terminals 29 and 30 are set at the same X-coordinate positions on the upper side of the pad 24 and the lower side of the input/output block 26, respectively. Thereafter, a wiring line for connecting the terminals set in the wiring process of step S13 is generated. At this time, if a wiring region is short, only the input/output blocks are moved, the pads are fixed to the positions initially given by the underlying frame file 51. FIG. 1A shows a layout after the wiring processing is finished. In FIG. 1A, the input/output block 3 is connected to the pad 5 near the corner block 4. FIG. 1B describes a specific input/output block 3a and a specificpad 5a. In FIG. 1B, the terminals 7 and 8 which are preset in terminal setting processing are connected to each other by a wiring line 6a.
In interwiring processing between the macro-blocks and between the macro-blocks and input/output blocks in step S5, interwiring processing between the macro-blocks and between the macro-blocks and the input/outputblocks is performed as in a conventional layout system. At this time, the wiring line is generated such that the positions of the input/output blocks are fixed not to be moved. As described above, the final chip overall layout 56 shown in FIG. 3 is obtained.
In the description of the above embodiment, once the pad positions are determined, they cannot be shifted. However, if the pad positions can be changed in relation to the input/output blocks to some extent, systematic wiring processing can be performed. A case wherein an interwiring means for performing wiring between input/output block and pads includes a meansfor performing the systematic wiring processing will be described below.
FIG. 11 shows an input/output environment of a system including the above means, and FIG. 12 shows an operation of the interwiring means for performing wiring between input/output blocks and pads. FIG. 12 is obtained by adding pad arrangement improving processing (step S22) to the flow chart of FIG. 5. The input/output environment of FIG. 11 is similar to that of FIG. 3 except for the content of an underlying frame file 51a. That is, arrangement coordinates of the pads in the underlying frame file 51a of FIG. 11 are different from that in the underlying frame file 51 of FIG. 3, and the coordinates of an initial arrangement and a movable range are stored in the underlying frame file 51a in relation to each pad.
FIG. 13 shows a positional relationship between an input/output block 31 and a pad 32. In FIG. 13, reference numeral 33 denotes a predicted wiring pattern represented by present arrangement coordinates, and reference numeral 34 denotes a movable range of the pad 32. In pad arrangement improving processing in step S22 of FIG. 12, when the bent wiring pattern 33 as shown in FIG. 13 is expected on the basis of a positional relationship between the pad and the input/output block in wiring pattern determination processing of step S21, the pad 32 is moved within the movable range 34. At this time, when the bent wiring pattern 33 can be changed into a linear wiring pattern 33a as shown in FIG. 14, processing for moving the pad 32 is performed. Therefore, the number of bent wiring patterns is decreased, and an increase in wiring area is prevented.
As has been described above, according to the method of the present invention, pads are separated from input/output blocks normally used in the layout of an LSI, and the input/output blocks and the pads are connected to each other with a wiring line. The input/output blocks can thus be arranged independently of the limitation of pad arrangement positions. Pads can be arranged near the corners of a chip. For this reason, the region of a peripheral chip portion can be effectively used, and a chip area can be advantageously decreased. | In the chip layout of an LSI, a layout near bonding pads is efficiently optimized. Especially in a chip having a large number of pins, an increase in chip size caused by pad necks can be prevented. Normal functional macro-blocks are arranged in an inner region of the LSI. On the other hand, input/output blocks including corner blocks are arranged at the peripheral portion of the LSI. In addition, pads separated from the input/output blocks are arranged on the LSI including portions near the corner blocks, and the input/output blocks and the pads are connected to each other through wiring lines. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to novel isoxazole and thiazole compounds (hereinafter referred to as an “azole compound”) or salt thereof. The azole compound of the present invention is useful as a lysophosphatidic acid (LPA) receptor antagonist and as a therapeutic or preventive agent for cell proliferative diseases, inflammatory diseases, kidney diseases, and cerebral or peripheral nerve disorders.
BACKGROUND ART
[0002] Lysophosphatidic acid (LPA) is a bioactive lysophospholipid which exists in organisms in very small amounts and is produced and released when various cells including platelets are stimulated by bioactive substances such as cytokines (J. Biol. Chem. 270: 12949 (1995); J. Biol. Chem. 267: 10988 (1992)). Therefore, it is believed that LPA concentration is elevated at sites of inflammation, hemorrhage or the like. Actually, it has been clarified that 2 to 20 μM of LPA is contained in blood serum and, in the case of a model of intracerebral hemorrhage, the LPA concentration in cerebral spinal fluid has been reported to be elevated to about 3 μM (J. Neurochem. 67: 2300 (1996)). Recently, elevated LPA concentration in human arteriosclerotic lesions was also reported (Proc. Natl. Acad. Sci. USA 96: 6931 (1999)). Further, elevated LPA concentration has been reported in the ascites of patients with peritoneal disseminated ovarian carcinoma and in the blood of patients with multiple myeloma (Lipids 34: 17 (1999); Gynecol. Oncol. 98: 71 (364)). While a site of action of LPA had not been heretofore clarified, the receptor specific for LPA was recently identified (Biochem. Biophys. Res. Commun. 231: 619 (1997)) and various biological activities of LPA, for example, cell proliferation, migration/invasion and platelet aggregation, have been elucidated as being effected through a cell membrane receptor. Regarding cell proliferation promoting activity, the effect of LPA has been reported in, for example, smooth muscle cells (Am. J. Physiol. 267: C204 (1994); Atherosclerosis 130: 121 (1997)), renal mesangial cells (Clinical Sci. 96: 431 (1999)), stellate cells of liver (Biochem. Biophys. Res. Commun. 191: 675 (1998)), fibroblasts (Naunyn-Schmiedeberg's Arch Pharmacol 355: 1 (1997)), and various carcinoma cells and abnormal proliferation of these cells caused by LPA is suggested to be associated with disease progression. Futhermore, the acceleration of migration activity in monocytes (J. Biol. Chem. 270: 25549 (1995)), activation of NF-KB in fibroblast (J. Biol. Chem. 274: 3828 (1999)) enhancement of fibronectin-binding to the cell surface (J. Biol. Chem. 274: 27257 (1999); J. Biol. Chem. 268: 23850 (1993)), promoting invasion of carcinoma cells (Biochem. Biophys. Res. Commun. 193: 497 (1993)) and the like have been observed. Thus, the association with various inflammatory diseases and the invasion and metastasis of carcinomas are suggested. Further, LPA has been reported as a causative agent in neurite retraction and cell death in neural cells, in particular, the possibility of LPA to be associated with neurodestruction after hemorrhage (J. Neurochem. 61: 340 (1993); J. Neurochem. 70: 66 (1998)).
[0003] The search for an agent to inhibit LPA-induced cell activation is considered the key elements leading to the prevention and treatment of restenosis after percutaneous transluminal coronary angioplasty (PTCA), arteriosclerosis, artery obstructions, malignant and benign proliferative diseases, various inflammatory diseases, kidney diseases, proliferation of tumor cells, invasion and metastasis of carcinomas, cerebral or periphery nerve disorders and the like. There has been heretofore no report on a low molecular weight compound having such inhibitory activities.
[0004] The object of the present invention is to provide a novel azole compound having an excellent LPA receptor antagonistic action and the application thereof to medicines.
SUMMARY OF THE INVENTION
[0005] The present inventors have conducted concentrated studies in order to develop a novel agent for inhibiting diseases caused by LPA and, as a result, found that a novel azole compound would inhibit actions effected through an LPA receptor. This has led to the completion of the present invention.
[0006] Specifically, the present invention comprises the following.
[0007] According to the first aspect, the present invention provides an azole compound represented by general formula [1] or salt thereof:
[0008] wherein
[0009] R1 represents an optionally substituted alkyl, aryl, heterocycle, alkyloxy, aryloxy, alkylthio, arylthio, or a halogen atom;
[0010] R2 represents an optionally substituted alkyl, aryl, heterocycle, alkyloxy, aryloxy, or a halogen atom;
[0011] R3 represents a hydrogen atom, lower alkyl, or alkyl halide;
[0012] R4 represents a group selected from the group consisting of (I) optionally substituted phenyl, aryl, or heterocycle, (II) substituted or nonsubstituted alkyl, and (III) substituted or nonsubstituted alkenyl,
[0013] alternativily, R3 and R4 may form a five- to ten-membered cyclic structure together with a carbon atom to which they bind; and
[0014] X represents an oxygen atom or a sulfur atom,
[0015] provided that, when R3 is a hydrogen atom, R4 represents a group other than methyl.
[0016] The present invention provides the azole compound represented by formula [1] or salt thereof, wherein R1 is a halogen atom or lower alkyl optionally substituted by one or more substituents selected from the group consisting of (I) alkyloxy, (II) alkylthio, (III) alkylamino, (IV) cyano, (V) nitro, (VI) cyclic amino, and (VII) a halogen atom; and
[0017] R2 is aryl or aromatic heterocycle optionally substituted by one or more substituents selected from the group consisting of:
[0018] (I) a halogen atom;
[0019] (II) lower alkyl optionally substituted by one or more substituents selected from the group consisting of (1) hydroxy, (2) thiol, (3) amino, (4) alkyloxy, (5) alkylthio, (6) alkylsulfinyl, (7) alkylsulfonyl, (8) monoalkylamino or dialkylamino, (9) acyloxy, (10) acylthio, (11) acylamino, (12) aryloxy, (13) arylthio, (14) arylsulfinyl, (15) arylsulfonyl, (16) arylamino, (17) alkylsulfonylamino or arylsulfonylamino, (18) alkylureide or arylureide, (19) alkyloxycarbonylamino or aryloxycarbonylamino, (20) alkylaminocarbonyloxy or arylaminocarbonyloxy, (21) carboxyl, (22) nitro, (23) heterocycle, (24) cyano, (25) cyclic amino, and (26) a halogen atom;
[0020] (III) optionally halogenated alkyloxy; (IV) optionally halogenated alkylthio; (V) cycloalkyl; (VI) aryl; (VII) aryloxy; (VIII) acylamino; (IX) acyloxy; (X) hydroxy; (XI) nitro; (XII) cyano; (XIII) amino; (XIV) monoalkylamino or dialkylamino; (XV) arylamino; (XVI) alkylsulfonylamino or arylsulfonylamino; (XVII) alkylureide or arylureide; (XVI) alkyloxycarbonylamino or aryloxycarbonylamino; (XIX) alkylaminocarbonyloxy or arylaminocarbonyloxy; (XX) alkyloxycarbonyl or aryloxycarbonyl; (XXI) acyl; (XXII) carboxyl; (XXII) carbamoyl; (XXIV) monoalkylcarbamoyl or dialkylcarbamoyl; (XXV) cyclic amino; and (XXVI) alkylsulfonyl or arylsulfonyl.
[0021] The present invention provides the azole compound represented by formula [1] or salt thereof, wherein
[0022] R1 is aryl or aromatic heterocycle optionally substituted by one or more substituents selected from the group consisting of:
[0023] (I) a halogen atom;
[0024] (II) lower alkyl optionally substituted by one or more substituents selected from the group consisting of (1) hydroxy, (2) thiol, (3) amino, (4) alkyloxy, (5) alkylthio, (6) alkylsulfinyl, (7) alkylsulfonyl, (8) monoalkylamino or dialkylamino, (9) acyloxy, (10) acylthio, (11) acylamino, (12) aryloxy, (13) arylthio, (14) arylsulfinyl, (15) arylsulfonyl, (16) arylamino, (17) alkylsulfonylamino or arylsulfonylamino, (18) alkylurcide or arylureide, (19) alkyloxycarbonylamino or aryloxycarbonylamino, (20) alkylaminocarbonyloxy or arylaminocarbonyloxy, (21) carboxyl, (22) nitro, (23) heterocycle, (24) cyano, (25) cyclic amino, and (26) a halogen atom;
[0025] (III) optionally halogenated alkyloxy; (IV) optionally halogenated alkylthio; (V) cycloalkyl; (VI) aryl; (VII) aryloxy; (VIII) acylamino; (IX) acyloxy; (X) hydroxy; (XI) nitro (XII) cyano; (XIII) amino; (XIV) monoalkylamino or dialkylamino; (XV) arylamino; (XVI) alkylsulfonylamino or arylsulfonylamino; (XVII) alkylureide or arylureide; (XVII) alkyloxycarbonylamino or aryloxycarbonylamino; (XIX) alkylaminocarbonyloxy or arylaminocarbonyloxy; (XX) alkyloxycarbonyl or aryloxycarbonyl; (XXI) acyl; (XXII) carboxyl; (XXIII) carbamoyl; (XXIV) monoalkylcarbamoyl or dialkylcarbamoyl; (XXV) cyclic amino; and (XXVI) alkylsulfonyl or arylsulfonyl; and
[0026] R2 is a halogen atom or lower alkyl optionally substituted by one or more substituents selected from the group consisting of (I) alkyloxy, (II) alkylthio, (III) alkylamino, (IV) cyano, (V) nitro, (VI) cyclic amino, and (VII) a halogen atom.
[0027] In one embodiment, the present invention provides the azole compound represented by general formula [2] or salt thereof:
[0028] wherein
[0029] R1, R3, and R4 are as defined above;
[0030] Y and Z are each independently a carbon atom or a nitrogen atom; and
[0031] R5, R6, R7, R8, and R9 are each independently selected from
[0032] (I) a hydrogen atom;
[0033] (II) a halogen atom;
[0034] (III) lower alkyl optionally substituted by one or more substituents selected from the group consisting of (1) hydroxy, (2) amino, (3) alkyloxy, (4) alkylthio, (5) alkylsulfinyl, (6) alkylsulfonyl, (7) monoalkylamino or dialkylamino, (8) acyloxy, (9) acylamino, (10) aryloxy, (11) arylthio, (12) arylsulfinyl, (13) arylsulfonyl, (14) arylamino, (15) alkylsulfonylamino or arylsulfonylamino, (16) alkylureide or arylureide, (17) alkyloxycarbonylamino or aryloxycarbonylamino, (18) alkylaminocarbonyloxy or arylaminocarbonyloxy, (19) cyano, (20) cyclic amino, and (21) a halogen atom;
[0035] (IV) optionally halogenated alkyloxy, (V) cycloalkyl, (VI) aryl, (VII) aryloxy, (VIII) acylamino, (IX) acyloxy, (X) hydroxy, (XI) nitro, (XII) cyano, (XIII) amino, (XIV) monoalkylamino or dialkylamino, (XV) arylamino, (XVI) alkylsulfonylamino or arylsulfonylamino, (XVII) alkylureide or arylureide, (XVIII) alkyloxycarbonylamino or aryloxycarbonylamino, (XIX) alkylaminocarbonyloxy or arylaminocarbonyloxy, (XX) alkyloxycarbonyl or aryloxycarbonyl, (XXI) acyl, (XXII) carboxyl, (XXIII) carbamoyl, (XXIV) monoalkylcarbamoyl or dialkylcarbamoyl, (XXV) cyclic amino, and (XXVI) alkylsulfonyl or arylsulfonyl,
[0036] provided that, when Y is a nitrogen atom, R6 is absent, and when Z is a nitrogen atom, R7 is absent.
[0037] The present invention provides the azole compound represented by formula [2] or salt thereof, wherein
[0038] R1 is methyl or ethyl;
[0039] R3 is a hydrogen atom, methyl, or trifluoromethyl;
[0040] R4 is phenyl optionally substituted by one or more substituents selected from the group consisting of (I) a halogen atom, (II) optionally halogenated lower alkyl, (III) optionally halogenated alkyloxy, (IV) optionally halogenated alkylthio, (V) cycloalkyl, (VI) aryl, (VII) aryloxy, (VIII) acylamino, (VIX) acyloxy, (X) hydroxy, (XI) nitro, (XII) cyano, (XIII) amino, (XIV) monoalkylamino or dialkylamino, (XV) arylamino, (XVI) alkylsulfonylamino or arylsulfonylamino, (XVII) alkylureide or arylureide, (XVIII) alkyloxycarbonylamino or aryloxycarbonylamino, (XIX) alkylaminocarbonyloxy or arylaminocarbonyloxy, (XX) alkyloxycarbonyl or aryloxycarbonyl, (XXI) acyl, (XXII) carboxyl, (XXIII) carbamoyl, (XXIV) monoalkylcarbamoyl or dialkylcarbamoyl, (XXV) cyclic amino, and (XXVI) alkylsulfonyl or arylsulfonyl;
[0041] Y and Z are a carbon atom; and
[0042] at least one of R6 and R7 is a halogen atom, chloromethyl, hydroxymethyl, cyano, trifluoromethoxy, a group represented by formula [3]:
[0043] wherein
[0044] n is 0 to 5;
[0045] Q is an oxygen atom, a sulfur atom, sulfinyl, or sulfonyl; and
[0046] R10 is selected from the group consisting of a hydrogen atom, a halogen atom, alkyl, alkyloxy, alkylthio, monoalkylamino or dialkylamino, aryloxy, arylthio, cyano, nitro, carboxyl, alkyloxycarbonyl or aryloxycarbonyl, carbamoyl, monoalkylcarbamoyl or dialkylcarbamoyl, acyl, aryl, cyclic amino, and heterocycle,
[0047] or a group represented by formula [4]:
[0048] wherein
[0049] n and m are each 0 to 5; and
[0050] R11 and R12 are each independently selected from the group consisting of a hydrogen atom, a halogen atom, alkyl, alkyloxy, alkylthio, monoalkylamino or dialkylamino, aryloxy, arylthio, hydroxy, cyano, nitro, carboxyl, alkyloxycarbonyl or aryloxycarbonyl, carbamoyl, monoalkylcarbamoyl or dialkylcarbamoyl, acyl, aryl, cyclic amino, and heterocycle; or R11 and R12 may together form a five- to nine-membered heterocycle containing, in addition to a nitrogen atom, 1 to 3 oxygen atoms or sulfur atoms.
[0051] In another embodiment, the present invention provides the azole compound represented by formula [5] or salt thereof:
[0052] wherein
[0053] R2, R3, and R4 are as defined above;
[0054] Y and Z are each independently a carbon atom or a nitrogen atom; and
[0055] R5, R6, R7, R8, and R9 are each independently selected from the group consisting of:
[0056] (I) a hydrogen atom;
[0057] (II) a halogen atom;
[0058] (III) lower alkyl optionally substituted by one or more substituents selected from the group consisting of (1) hydroxy, (2) amino, (3) alkyloxy, (4) alkylthio, (5) alkylsulfinyl, (6) alkylsulfonyl, (7) monoalkylamino or dialkylamino, (8) acyloxy, (9) acylamino, (10) aryloxy, (11) arylthio, (12) arylsulfinyl, (13) arylsulfonyl, (14) arylamino, (15) alkylsulfonylamino or arylsulfonylamino, (16) alkylureide or arylureide, (17) alkyloxycarbonylamino or aryloxycarbonylamino, (18) alkylaminocarbonyloxy or arylaminocarbonyloxy, (19) cyano, (20) cyclic amino, and (21) a halogen atom;
[0059] (IV) optionally halogenated alkyloxy, (V) cycloalkyl, (VI) aryl, (VII) aryloxy, (VIII) acylamino, (IX) acyloxy, (X) hydroxy, (XI) nitro, (XII) cyano, (XIII) amino, (XIV) monoalkylamino or dialkylamino, (XV) arylamino, (XVI) alkylsulfonylamino or arylsulfonylamino, (XVII) alkylureide or arylureide, (XVIII) alkyloxycarbonylamino or aryloxycarbonylamino, (XIX) alkylaminocarbonyloxy or arylaminocarbonyloxy, (XX) alkyloxycarbonyl or aryloxycarbonyl, (XXI) acyl, (XXII) carboxyl, (XXIII) carbamoyl, (XXIV) monoalkylcarbamoyl or dialkylcarbamoyl, (XXV) cyclic amino, and (XXVI) alkylsulfonyl or arylsulfonyl,
[0060] provided that, when Y is a nitrogen atom, R6 is absent, and when Z is a nitrogen atom, R7 is absent.
[0061] The present invention provides the azole compound represented by formula [5] or salt thereof, wherein
[0062] R2 is methyl or ethyl;
[0063] R3 is a hydrogen atom, methyl, or trifluoromethyl;
[0064] R4 is phenyl optionally substituted by one or more substituents selected from the group consisting of (I) a halogen atom, (II) optionally halogenated lower alkyl, (III) optionally halogenated alkyloxy, (IV) optionally halogenated alkylthio, (V) cycloalkyl, (VI) aryl, (VII) aryloxy, (VIII) acylamino, (VIX) acyloxy, (X) hydroxy, (XI) nitro, (XII) cyano, (XIII) amino, (XIV) monoalkylamino or dialkylamino, (XV) arylamino, (XVI) alkylsulfonylamino or arylsulfonylamino, (XVII) alkylureide or arylureide, (XVIII) alkyloxycarbonylamino or aryloxycarbonylarmino, (XIX) alkylaminocarbonyloxy or arylaminocarbonyloxy, (XX) alkyloxycarbonyl or aryloxycarbonyl, (XXI) acyl, (XXII) carboxyl, (XXIII) carbamoyl, (XXIV) monoalkylcarbamoyl or dialkylcarbamoyl, (XXV) cyclic amino, and (XXVI) alkylsulfonyl or arylsulfonyl;
[0065] Y and Z are each independently a carbon atom; and
[0066] at least one of R6 and R7 is a halogen atom, chloromethyl, hydroxymethyl, cyano, trifluoromethoxy, a group represented by formula [3]:
[0067] wherein
[0068] n is 0 to 5;
[0069] Q is an oxygen atom, a sulfur atom, sulfinyl, or sulfonyl; and
[0070] R10 is selected from the group consisting of a hydrogen atom, a halogen atom, alkyl, alkyloxy, alkylthio, monoalkylamino or dialkylamino, aryloxy, arylthio, cyano, nitro, carboxyl, alkyloxycarbonyl or aryloxycarbonyl, carbamoyl, monoalkylcarbamoyl or dialkylcarbamoyl, acyl, aryl, cyclic amino, and heterocycle, or a group represented by formula [4]:
[0071] wherein
[0072] n and m are each 0 to 5; and
[0073] R11 and R12 are each independently selected from the group consisting of a hydrogen atom, a halogen atom, alkyl, alkyloxy, alkylthio, monoalkylamino or dialkylamino, aryloxy, arylthio, hydroxy, cyano, nitro, carboxyl, alkyloxycarbonyl or aryloxycarbonyl, carbamoyl, monoalkylcarbamoyl or dialkylcarbamoyl, acyl, aryl, cyclic amino, and heterocycle; or R11 and R12 may together form a five- to nine-membered heterocycle containing, in addition to a nitrogen atom, 1 to 3 oxygen atoms or sulfur atoms.
[0074] The present invention provides the azole compound represented by formula [2] or [5] or salt thereof, wherein R4 is phenyl optionally substituted by one or more substituents selected from the group consisting of (I) a halogen atom, (II) optionally halogenated lower alkyl, (III) optionally halogenated alkyloxy, (IV) optionally halogenated alkylthio, (VIII) acylamino, (X) hydroxy, (XI) nitro, (XII) cyano, (XIII) amino, (XIV) monoalkylamino or dialkylamino, (XX) alkyloxycarbonyl or aryloxycarbonyl, (XXI) acyl, (XXII) carboxyl, and (XXV) cyclic amino.
[0075] The present invention provides the azole compound represented by formula [2] or [5] or salt thereof, wherein R4 is a nonsubstituted phenyl, 2-chlorophenyl, 2-bromophenyl, or 2-fluorophenyl.
[0076] According to the second aspect, the present invention provides a lysophosphatidic acid (LPA) receptor antagonist comprising, as an active ingredient, the above novel azole compound or salt thereof.
[0077] According to the third aspect, the present invention provides a therapeutic or preventive agent for cell proliferative diseases comprising, as an active ingredient, the above novel azole compound or salt thereof.
[0078] According to the fourth aspect, the present invention provides a therapeutic or preventive agent for inflammatory diseases comprising, as an active ingredient, the above novel azole compound or salt thereof.
[0079] According to the fifth aspect, the present invention provides a therapeutic or preventive agent for kidney diseases comprising, as an active ingredient, the above novel azole compound or salt thereof.
[0080] According to the sixth aspect, the present invention provides a therapeutic or preventive agent for cerebral or peripheral nerve disorders comprising, as an active ingredient, the above novel azole compound or salt thereof.
[0081] According to the seventh aspect, the present invention provides a therapeutic or preventive agent for artery obstructions comprising, as an active ingredient, the above novel azole compound or salt thereof.
[0082] According to the eighth aspect, the present invention provides an antitumor agent comprising, as an active ingredient, the above novel azole compound or salt thereof.
BRIEF DESCRIPTION OF DRAWINGS
[0083] [0083]FIG. 1A to FIG. 1I show structures of Compound 103 to Compound 169 (in Examples 103 to 169 below).
[0084] [0084]FIG. 2A and FIG. 2B show the inhibitory action of Compound 115 against the proliferation of cultured carcinoma cells by LPA. FIG. 2A shows the inhibition of the proliferation of human brain tumor cells and FIG. 2B shows the inhibition of the proliferation of human ovarian carcinoma cells.
DETAILED DESCRIPTION OF THE INVENTION
[0085] The term “optionally substituted” used herein means that the group of interest may optionally have one or more substituents. The term “optionally halogenated” means that the group of interest may be optionally substituted by at least one halogen atom.
[0086] Examples of a halogen atom, various groups, and substituents according to the present invention used herein include, but not limited to, the following.
[0087] Examples of a halogen atom include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom.
[0088] Examples of alkyl include straight chain or branched C 1-20 alkyl such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, and eicosyl.
[0089] Examples of cycloalkyl include C 3-6 cycloalkyl such as cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl.
[0090] Examples of alkoxy include straight chain or branched C 1-20 alkoxy such as methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, sec-butoxy, tert-butoxy, pentyloxy, hexyloxy, heptyloxy, and octyloxy.
[0091] Examples of aryl include phenyl, tolyl, and naphthyl.
[0092] Examples of aryloxy include aryl-O— such as phenoxy, tolyloxy, and naphthyloxy.
[0093] Examples of heterocycle include aromatic heterocycle and nonaromatic heterocycle, for example, four- to seven-membered or fused heterocycle containing at least one hetero atom selected from an oxygen atom, a nitrogen atom, and a sulfur atom such as azetidinyl, thienyl, furyl, pyrrolyl, imidazolyl, pyrazolyl, thiazolyl, isothiazolyl, oxazolyl, isoxazolyl, furazanyl, pyrrolidinyl, pyrrolinyl, imidazolydinyl, imidazolinyl, pyrazolydinyl, pyrazolinyl, 1,3,4-oxadiazolyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,3,4-thiadiazolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, tetrazolyl, thiatriazolyl, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, piperidinyl, piperazinyl, pyranyl, morpholinyl, 1,2,4-triazinyl, benzothienyl, naphthothienyl, benzofuryl, isobenzofuryl, chromenyl, indolizinyl, isoindolyl, indolyl, indazolyl, purinyl, quinolyl, isoquinolyl, phthalazinyl, naphthylizinyl, quinoxalinyl, quinazolinyl, cinnolinyl, pteridinyl, acridinyl, isochromanyl, chromanyl, indolinyl, isoindolinyl, benzoxazolyl, triazolopyridyl, tetrazolopyridazinyl, tetrazolopyrimidinyl, thiazolopyridazinyl, thiadiazolopyridazinyl, triazolopyridazinyl, benzimidazolyl, benzthiazolyl, benzothiadiazolyl, 1,2,3,4-tetrahydroquinolyl, imidazo[1,2-b][1,2,4]triazinyl, and quinuclidinyl.
[0094] Examples of acyl include acyl such as formyl, C 2-12 alkanoyl such as acetyl or propionyl, aroyl such as benzoyl or naphthoyl, and heterocyclic carbonyl such as nicotinoyl, thenoyl, pyrrolidino carbonyl, or furoyl.
[0095] Examples of monoalkylamino or dialkylamino include mono- or di-straight chain or branched C 1-6 alkylamino such as methylamino, ethylamino, n-propylamino, isopropylamino, n-butylamino, sec-butylamino, tert-butylamino, pentylamino, hexylamino, dimethylamino, diethylamino, di-n-propylamino, ethylmethylamino, methyl n-propylamino, and butylethylamino.
[0096] Examples of cyclic amino include five- to nine-membered cyclic amino optionally containing, in addition to a nitrogen atom, 1 to 3 hetero atoms such as an oxygen atom or a sulfur atom, for example, pyrrolidino, piperidino, morpholino, and iomorpholino.
[0097] Examples of lower alkyl include straight chain or branched C 1-6 alkyl such as methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, and pentyl.
[0098] In general formula [1], [2] or [5], R3 and R4 may form a five- to ten-membered cyclic structure together with a carbon atom to which they bind. Such structures include, for example, optionally substituted saturated or unsaturated monocyclic or fused polycyclic hydrocarbon and monocyclic or fused heterocycle containing hetero atoms such as a nitrogen atom, an oxygen atom, or a sulfur atom, such as cyclohexenyl, indanyl, or tetrahydronaphthyl.
[0099] The salt of the compound of the present invention includes conventional salt, for example, salt of a basic group such as amino or salt of an acidic group such as carboxyl. Examples of a salt of basic group include: salt with mineral acid such as hydrochloric acid, sulfuric acid, nitric acid, and phosphoric acid; salt with organic carboxylic acid such as formic acid, acetic acid, trichloroacetic acid, trifluoroacetic acid, oxalic acid, fumaric acid, maleic acid, citric acid, and tartaric acid; and salt with sulfonic acid such as methanesulfonic acid, benzenesulfonic acid, p-toluenesulfonic acid, and naphthalenesulfonic acid. Examples of a salt of acidic group include: salt with alkali metal such as sodium and potassium; salt with alkaline earth metal such as calcium and magnesium; ammonium salt; and salt with nitrogen-containing organic base such as trimethylamine, triethylamine, tributylamine, N,N-dimethylaniline, N-methylpipefidine, N-methylmorpholine, diethylamine, dicyclohexylamine, dibenzylamine, pyridine, guanidine, hydrazine, and quinine. The salt of the compound of the present invention preferably includes pharmaceutically acceptable salt of, for example, hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, formic acid, acetic acid, oxalic acid, fumaric acid, maleic acid, citric acid, sulfonic acid, and tartaric acid.
[0100] The method for producing the azole compound of the present invention will be described below.
[0101] The azole compound represented by general formula [1] can be produced utilizing the Curtius rearrangement shown in the following Reaction path (I).
[0102] In this method, the starting material, an azole carboxylic acid, was dissolved in a suitable solvent (e.g., toluene) and was reacted with an azide compound (e.g., diphenyl phosphoryl azide ) to produce isocyanate. Thereafter, the isocyanate was reacted with a suitable alcohol to produce carbamate (Reaction path (I)).
[0103] In the Reaction path (I), R1, R2, R3, and R4 are as defined above.
[0104] The starting material, which is necessary for synthesizing the compound of the present invention, is commercially available or can be produced by the Reaction path (II) shown below (Synthesis, 1994, (9), 898 and thereinafter and Heterocycles, 1995, (41), 175 and thereinafter) or a conventional method shown in Reaction path (III).
[0105] In the Reaction path (II), R1 and R2 are as defined above and R13 represents straight chain or branched lower alkyl.
[0106] In the Reaction path (III), R1, R2, and R13 are as defined above.
[0107] The compounds and the salts thereof according to the present invention are useful as an antagonist on lysophosphatidic acid (LPA) receptor and exhibit excellent actions as preventive and therapeutic agents for restenosis after percutaneous transluminal coronary angioplasty (PTCA), arteriosclerosis, artery obstruction, malignant and benign proliferative diseases, various inflammatory diseases, kidney diseases, proliferation of tumor cells, invasion and metastasis of carcinoma, cerebral or periphery nerve disorders and the like. Regarding the association between the LPA and the disease state, reference can be made to the literature cited in the section of the BACKGROUND ART.
[0108] When the compound of the present invention is used as a medicine, pharmaceutic aids such as an excipient, a carrier, and a diluent, which are commonly used in the preparation of formulations, may be suitably mixed. The compound can be orally or parenterally administered through conventional forms, for example, tablets, powders, granules, pills, suspensions, capsules, syrups, emulsions, liquid formulations, powder formulations, suppositories, ointments, patches, or injections. The method of administration, the dosage, and the frequency of administration, can be suitably selected depending on the age, weight, and symptom of the patient. In general, the administration can be orally or parenterally carried out (for example, by injection, drip infusion, percutaneous administration, or administration at rectal site) in the range of 0.1 to 5,000 mg, preferably in the range of 1 to 1,000 mg, per day to an adult, in a single dose or several separate doses.
[0109] The above-described various agents are formulated according to conventional methods. For example, when formulated into the form of solid formulations for oral administration such as tablets, powders, and granules, carriers usable herein include: excipients such as lactose, saccharose, sodium chloride, glucose, starch, calcium carbonate, kaolin, crystalline cellulose, calcium hydrogenphosphate, and alginic acid; binders such as simple syrup, liquid glucose, a starch solution, a gelatin solution, polyvinyl alcohol, polyvinyl ether, polyvinyl pyrrolidone, carboxymethylcellulose, shellac, methylcellulose, ethylcellulose, sodium alginate, gum Arabic, hydroxypropylmethylcellulose, hydroxypropylcellulose, water, and ethanol; disintegrating agents such as dried starch, alginic acid, agar powder, starch, crosslinking polyvinylpyrrolidone, crosslinking carboxymethylcellulose sodium, carboxymethylcellulose calcium, and sodium starch glycolate; disintegration inhibitors such as stearyl alcohol, stearic acid, cocoa butter, and hydrogenated oil; absorbefacients such as quaternary ammonium salt and sodium lauryl sulfate; absorbents such as starch, lactose, kaolin, bentonite, silicic anhydride, hydrous silicon dioxide, magnesium aluminometasilicate, and colloidal silica; and lubricants such as purified talc, stearate, and polyethylene glycol.
[0110] If necessary, conventional coatings may be applied to make tablets, for example, a sugar-coated tablet, a gelatin-encapsulated tablet, a gastric coated tablet, an enteric coated tablet, or a water-soluble film-coated tablet.
[0111] The capsule form can be prepared through mixing with various carriers as mentioned above, followed by filling into a hard gelatin capsule, a soft capsule or the like.
[0112] The liquid formulation can be an aqueous or oleaginous suspension, a solution, a syrup, or an elixir and can be prepared in accordance with conventional methods using conventional additives.
[0113] When formulated into the form of a suppository, a suitable absorbefacient can be added as a carrier, for example, polyethylene glycol, cocoa butter, lanoline, higher alcohol, esters of higher alcohol, gelatin, semi-synthetic glyceride, or Witepsol (registered trademark: Dynamite Novel).
[0114] When formulated into an injectable form, examples of carriers usable herein include: diluents such as water, ethyl alcohol, macrogol, propylene glycol, citric acid, acetic acid, phosphoric acid, lactic acid, sodium lactate, sulfuric acid, and sodium hydroxide; pH adjusters and buffers such as sodium citrate, sodium acetate, and sodium phosphate; and stabilizers such as sodium pyrosulfite, ethylenediaminetetraacetic acid, thioglycolic acid, and thiolactic acid. In this case, salt, glucose, mannitol, or glycerin may be contained in a medical formulation in a sufficient amount to prepare an isotonic solution and a conventional solubilizer, soothing agent, local anesthetic or the like may be added.
[0115] When formulated into the form of ointments, for example, paste, cream, and gel, a commonly used base, stabilizer, wetting agent, preservative and the like are optionally compounded and, in accordance with a conventional method, mixed and prepared. Examples of the bases usable herein include white petrolatum, polyethylene, paraffin, glycerin, cellulose derivative, polyethylene glycol, silicon, and bentonite. Preservatives usable herein include methyl p-hydroxybenzoate, ethyl p-hydroxybenzoate, and propyl p-hydroxybenzoate.
[0116] The present invention will be described in more detail with reference to the following examples. These examples, however, are not intended to limit the scope of the present invention. With reference to the description on the present invention and the following specific examples, a person who has ordinary skill in the art would be able to develop various compounds included in the scope of the present invention or the scope equivalent thereto and could confirm the effects thereof. Accordingly, the present invention is intended to include, unless departing from the scope of the invention specified in the claims, any scopes equivalent to the scope of the present invention.
EXAMPLES
Example 1
[0117] Synthesis of Compound 1: 3-Furylmethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0118] 5-Methyl-3-phenyl-4-isoxazole carboxylic acid (50 mg) was dissolved in anhydrous toluene (1.0 ml). Subsequently, diphenylphosphoryl azide (81 mg) and triethylamine (30 mg) were added at room temperature and the mixture was stirred at 120° C. for 1 hour. After the mixture was allowed to stand at room temperature, 3-furanmethanol (24 mg) was added thereto and the mixture was stirred again at 120° C. for 2 hours. After the completion of the reaction, the mixture was allowed to cool at room temperature and distilled water was added thereto. Thereafter, the reaction product was extracted by liquid separation using chloroform and washed with saturated solution of sodium chloride. The product was dried over sodium sulfate to concentrate and the residue was purified by silicagel column chromatography using a hexane-acetone elution system. Thus, the title compound 1 (29 mg, yield 40.0%) was obtained.
[0119] [0119] 1 H-NMR (CDCl 3 , 400 MHz): δ7.39-7.65 (5H, m), 6.23-6.47 (2H, m), 4.55-4.58 (3H, m), 1.61 (3H, s)
[0120] Mass spectrometry (FD-MS): 298 (M + )
Example 2
[0121] Synthesis of Compound 2: Benzyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0122] The title compound 2 was obtained in the same manner as used in Example 1.
[0123] [0123] 1 H-NMR (CDCl 3 , 400 MHz): δ7.61 (7H, d, J=6.83 Hz), 7.39 (2H, m), 4.91 (3H, bs), 2.17 (3H, bs)
[0124] Mass spectrometry (ESI-MS): 309 (M + 1)
Example 3
[0125] Synthesis of Compound 3: 1-(2-Chlorophenyl)ethyl N-(3-methyl-5-phenyl-4-isoxazolyl)carbamate
[0126] Acetaldoxime (500 mg) was dissolved in dimethylformamide (2 ml), and under ice cooling, N-bromosuccinimide (1.66 g) dissolved in dimethylformamide (4 ml) was added dropwise. The mixture was stirred at 0° C. for 30 minutes, a methanol solution comprising ethyl benzoylacetate (3.26 g) and metallic sodium (700 mg) was added thereto, and the mixture was stirred at that temperature for 1 hour. After the completion of the reaction, distilled water was added thereto, and the reaction product was extracted by liquid separation using ethyl acetate and washed with saturated solution of sodium chloride. The product was dried over sodium sulfate to concentrate, and the residue was purified by flash column chromatography using a hexane-ethyl acetate elution system. Thus, a useful intermediate, i.e., ethyl 3-methyl-5-phenyl-4-isoxazole carboxylate (1.45 g, yield 74.4%) was obtained.
[0127] The ethyl 3-methyl-5-phenyl-4-isoxazole carboxylate (1.45 g) obtained in the above reaction was dissolved in ethanol (45 ml) and distilled water (15 ml), potassium hydroxide (1.3 g) was added thereto at room temperature, and the mixture was stirred under heat reflux for 1 hour. After the completion of the reaction, the mixture was concentrated to remove ethanol, distilled water was added thereto, and the mixture was acidified (pH=4) using 1%-aqueous hydrochloric acid. Extraction by liquid separation using dichloromethane and washing with a saturated saline solution were then performed. The product was dried over sodium sulfate followed by concentration and the residue was purified by silica gel column chromatography using a chloroform-methanol elution system. Thus, 3-methyl-5-phenyl-4-isoxazole carboxylic acid (215 mg, yield 16.9%), a starting compound for the Curtius reaction described in Example 1, was obtained.
[0128] 3-Methyl-5-phenyl-4-isoxazole carboxylic acid (70 mg) was dissolved in anhydrous toluene (0.7 ml). Subsequently, diphenylphosphoryl azide (89 μl) and triethylamine (58 μl) were added at room temperature and the mixture was stirred at 120° C. for 1 hour. After the mixture was allowed to stand at room temperature, 2-chloro-α-methyl benzyl alcohol (46 μl) was added, and the mixture was stirred again at 120° C. for 2 hours. After the completion of the reaction, the mixture was allowed to cool at room temperature and distilled water was added thereto. Thereafter the reaction product was extracted by liquid separation using chloroform and washed with saturated solution of sodium chloride. The product was dried over sodium sulfate to concentrate and the residue was purified by silica gel column chromatography using a hexane-acetone elution system. Thus, the title compound 3 (18 mg, yield 14.6%) was obtained.
[0129] [0129] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.85 (9H, m), 6.15-6.25 (2H, m), 2.23 (3H, s), 1.30-1.70 (3H, m)
[0130] Mass spectrometry (FD-MS): 356 (M + )
Example 4
[0131] Synthesis of Compound 4: 1-(2-Chlorophenyl)ethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0132] The title compound 4 was obtained in the same manner as used in Example 1.
[0133] [0133] 1 H-NMR (CDCl 3 , 400 MHz): δ7.25-7.80 (9H, m), 6.19 (1H, bs), 5.88 (1H, bs), 2.40 (3H, s), 1.52-1.65 (3H, m)
[0134] Mass spectrometry (FD-MS): 356 (M + )
Example 5
[0135] Synthesis of Compound 5: 1-(2-Chlorophenyl)ethyl N-[5-methyl-3-(4-methylphenyl)-4-isoxazolyl]carbamate
[0136] The title compound 5 was obtained in the same manner as used in Example 3.
[0137] [0137] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.70 (8H, in), 6.18 (1H, bs), 5.87 (1H, bs), 2.40 (3H, s), 2.39 (3H, s), 1.50-1.64 (3H, m)
[0138] Mass spectrometry (FD-MS): 371 (M + )
Example 6
[0139] Synthesis of Compound 6: 1-(2-Chlorophenyl)ethyl N-[5-methyl-3-(4-nitrophenyl)-4-isoxazolyl]carbamate
[0140] The title compound 6 was obtained in the same manner as used in Example 3.
[0141] Mass spectrometry (FD-MS): 401 (M + )
Example 7
[0142] Synthesis of Compound 7: Benzyl N-(3-methyl-5-phenyl-4-isoxazolyl)carbamate
[0143] The title compound 7 was obtained in the same manner as used in Example 3.
[0144] [0144] 1 H-NMR (CDCl 3 , 400 MHz): δ7.40-7.80 (10H, m), 6.00 (1H, bs), 5.22 (2H, s), 2.27 (3H, s)
[0145] Mass spectrometry (FD-MS): 308 (M + )
Example 8
[0146] Synthesis of Compound 8: 1-(2-Chlorophenyl)ethyl N-[3-[4-(hydroxymethyl)phenyl]-5-methyl-4-isoxazolyl] carbamate
[0147] The title compound 8 was obtained in the same manner as used in Example 3.
[0148] [0148] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.70 (8H, m), 6.18 (1H, bs), 5.96 (1H, bs), 4.73 (2H, s), 2.39 (3H, s), 1.50-1.78 (3H, m)
[0149] Mass spectrometry (FD-MS): 386 (M + )
Example 9
[0150] Synthesis of Compound 9: (1R)-1-Phenylethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0151] The title compound 9 was obtained in the same manner as used in Example 1.
[0152] [0152] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.70 (10H, m), 5.85 (1H, bs), 2.37 (3H, s), 1.58 (3H, bs)
[0153] Mass spectrometry (FD-MS): 322 (M + )
Example 10
[0154] Synthesis of Compound 10: (1S)-1-Phenylethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0155] The title compound 10 was obtained in the same manner as used in Example 1.
[0156] [0156] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.70 (10H, m), 5.85 (1H, bs), 2.37 (3H, s), 1.58 (3H, bs)
[0157] Mass spectrometry (FD-MS): 322 (M + )
Example 11
[0158] Synthesis of Compound 11: 1-(2-Chlorophenyl)ethyl N-[5-methyl-3-[4-(trifluoromethoxy)phenyl]-4-isoxazolyl]carbamate
[0159] The title compound 11 was obtained in the same manner as used in Example 3.
[0160] [0160] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (8H, m), 6.18 (1H, bs), 5.87 (1H, bs), 2.41 (3H, s), 1.50-1.65 (3H, m)
[0161] Mass spectrometry (FD-MS): 440 (M + )
Example 12
[0162] Synthesis of Compound 12: 1-Phenylethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0163] The title compound 12 was obtained in the same manner as used in Example 1.
[0164] [0164] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.70 (10H, m), 5.85 (1H, bs), 2.38 (3H, s), 1.52-1.66 (3H, m)
[0165] Mass spectrometry (FD-MS): 322 (M + )
Example 13
[0166] Synthesis of Compound 13: 1-(2-Chlorophenyl)ethyl N-[3-(3-bromophenyl)-5-methyl-4-isoxazolyl]carbamate
[0167] The title compound 13 was obtained in the same manner as used in Example 3.
[0168] [0168] 1 H-NMR (CDCl 3 , 400 MHz): δ7.85 (1H, s), 7.26-7.60 (7H, M), 6.18 (1H, bs), 5.88 (1H, bs), 2.40 (3H, s), 1.50-1.65 (3H, m)
[0169] Mass spectrometry (FD-MS): 436 (M + )
Example 14
[0170] Synthesis of Compound 14: 1-(2-Methylphenyl)ethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0171] The title compound 14 was obtained in the same manner as used in Example 3.
[0172] [0172] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.70 (9H, m), 6.05 (1H, bs), 5.84 (1H, bs), 2.38 (3H, s), 2.38 (3H, s), 1.54 (3H, bs)
[0173] Mass spectrometry (FD-MS): 336 (M + )
Example 15
[0174] Synthesis of Compound 15: 1-(2-Chlorophenyl)ethyl N-[5-methyl-3-[3-(trifluoromethyl)phenyl]-4-isoxazolyl]carbamate
[0175] The title compound 15 was obtained in the same manner as used in Example 3.
[0176] [0176] 1 H-NMR (CDCl 3 , 400 MHz): δ7.98 (1H, s), 7.86 (1H, d, J=7.6 Hz), 7.71 (1H, d, J=8.0 Hz), 7.20-7.58 (5H, m), 6.19 (1H, bs), 5.89 (1H, bs), 2.42 (3H, s), 1.50-1.65 (3H, m)
[0177] Mass spectrometry (FD-MS): 424 (M + )
Example 16
[0178] Synthesis of Compound 16: 1-(2-Chlorophenyl)ethyl N-[3-(4-fluorophenyl)-5-methyl-4-isoxazolyl] carbamate
[0179] The title compound 16 was obtained in the same manner as used in Example 3.
[0180] [0180] 1 H-NMR (CDCl 3 , 400 MHz): δ7.07-7.70 (8H, m), 6.18 (1H, bs), 5.85 (1H, bs), 2.40 (3H, s), 1.50-1.65 (3H, m)
[0181] Mass spectrometry (FD-MS): 374 (M + )
Example 17
[0182] Synthesis of Compound 17: (1R)-1-(2-Chlorophenyl)ethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0183] The title compound 17 was obtained in the same manner as used in Example 1.
[0184] [0184] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.72 (9H, m), 6.19 (1H, bs), 5.88 (1H, bs), 2.41 (3H, s), 1.52-1.65 (3H, m)
[0185] Mass spectrometry (FD-MS): 356 (M + )
Example 18
[0186] Synthesis of Compound 18: (1R)-1-(2-Chlorophenyl)ethyl N-(3-methyl-5-phenyl-4-isoxazolyl)carbamate
[0187] The title compound 18 was obtained in the same manner as used in Example 3.
[0188] Mass spectrometry (FD-MS): 356 (M + )
Example 19
[0189] Synthesis of Compound 19: 1-(2-Fluorophenyl)ethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0190] The title compound 19 was obtained in the same manner as used in Example 1.
[0191] [0191] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.70 (9H, m), 6.08 (1H, bs), 5.87 (1H, bs), 2.37 (3H, s), 1.50-1.70 (3H, m)
[0192] Mass spectrometry (ESI-MS): 341, 342 (M + +1)
Example 20
[0193] Synthesis of Compound 20: 1-(2-Chlorophenyl)ethyl N-[3-(2-fluorophenyl)-5-methyl-4-isoxazolyl]carbamate
[0194] The title compound 20 was obtained in the same manner as used in Example 3.
[0195] [0195] 1 H-NMR (CDCl 3 , 400 MHz): δ7.16-7.65 (8H, m), 6.05-6.15 (2H, m), 2.41 (3H, s), 1.50-1.58 (3H, m)
[0196] Mass spectrometry (FD-MS): 374 (M + )
Example 21
[0197] Synthesis of Compound 21: 1-(2-Chlorophenyl)ethyl N-[3-(3-fluorophenyl)-5-methyl-4-isoxazolyl]carbamate
[0198] The title compound 21 was obtained in the same manner as used in Example 3.
[0199] [0199] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.50 (8H, m), 6.18 (1H, bs), 5.89 (1H, bs), 2.40 (3H, s), 1.50-1.65 (3H, m) Mass spectrometry (FD-MS): 374 (M + )
Example 22
[0200] Synthesis of Compound 22: (1R)-1-(2-Bromophenyl)ethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0201] The title compound 22 was obtained in the same manner as used in Example 1.
[0202] [0202] 1 H-NMR (CDCl 3 , 400 MHz): δ6.75-7.70 (9H, m), 6.06 (1H, bs), 5.81 (1H, bs), 2.33 (3H, s), 1.20-1.70 (3H, m)
[0203] Mass spectrometry (FD-MS): 400, 402 (M + )
Example 23
[0204] Synthesis of Compound 23: 1-(2-Bromophenyl)ethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0205] The title compound 23 was obtained in the same manner as used in Example 1.
[0206] [0206] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.70 (9H, m), 6.11 (1H, bs), 5.86 (1H, bs), 2.38 (3H, s), 1.45-1.62 (3H, m)
[0207] Mass spectrometry (ESI-MS): 403 (M + +1)
Example 24
[0208] Synthesis of Compound 24: (1R)-1-(2-Bromophenyl)ethyl N-[3-chloro-5-(2-chlorophenyl)-4-isothiazolyl]carbamate
[0209] The title compound 24 was obtained in the same manner as used in Example 1.
[0210] [0210] 1 H-NMR (CDCl 3 , 400 MHz): δ7.10-7.52 (8H, m), 6.21 (1H, bs), 5.99 (1H, q, J=6.5 Hz), 1.40-1.50 (3H, m)
[0211] Mass spectrometry (FD-MS): 470, 472 (M + )
Example 25
[0212] Synthesis of Compound 25: 1-Phenylethyl N-[3-chloro-5-(2-chlorophenyl)-4-isothiazolyl]carbamate
[0213] The title compound 25 was obtained in the same manner as used in Example 1.
[0214] [0214] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.60 (9H, m), 6.21 (1H, bs), 5.73 (1H, q, J=6.6 Hz), 1.40-1.50 (3H, m)
[0215] Mass spectrometry (FD-MS): 392 (M + )
Example 26
[0216] Synthesis of Compound 26: 1-(2-Fluorophenyl)ethyl N-[3-chloro-5-(2-chlorophenyl)-4-isothiazolyl]carbamate
[0217] The title compound 26 was obtained in the same manner as used in Example 1.
[0218] [0218] 1 H-NMR (CDCl 3 , 400 MHz): δ6.98-7.50 (8H, m), 5.97 (1H, q, J=6.6 Hz), 1.45-1.52 (3H, m)
[0219] Mass spectrometry (FD-MS): 410 (M + )
Example 27
[0220] Synthesis of Compound 27: 1-Phenylethyl N-[3-methyl-5-(3-methylphenyl)-4-isoxazolyl]carbamate
[0221] Methyl 3-oxobutanoate (29.4 g) was dissolved in methanol (30 ml), then a 40%-methylamine-methanol solution (32 ml) was added dropwise at room temperature, and the mixture was stirred for 1 hour. After the completion of the reaction, the reaction solution as such was concentrated, and then dried using a vacuum pump to obtain methyl 3-(methylamino)-2-butenoate (31.8 g, yield 97%). Subsequently, methyl 3-(methylamino)-2-butenoate (1.0 g) was dissolved in tetrahydrofuran (15 ml) and pyridine (0.63 ml) was added dropwise at room temperature. Under ice cooling, m-toluyl chloride (1.22 ml) was added dropwise and the mixture was stirred at room temperature for 1 hour. After the completion of the reaction, distilled water was added, and the reaction product was extracted by liquid separation using ether and then washed with a saturated saline solution. The product was dried over sodium sulfate to concentrate and the residue was dried using a vacuum pump. Subsequently, the residue was dissolved in an acetic acid (15 ml). Then, hydroxylamine hydrochloride (0.54 g) was added at room temperature, and the product was heated under reflux for 30 minutes. After the completion of the reaction, saturated aqueous solution of sodium hydrogencarbonate was added to neutralize the reaction system, and the product was extracted by liquid separation using ether. The resultant organic layer was washed with saturated aqueous solution of sodium chloride and dried over sodium sulfate to concentrate. The residue was purified by silica gel column chromatography using a hexane-acetone elution system to obtain methyl 3-methyl-5-(3-methylphenyl)-4-isoxazole carboxylate (183 mg, yield 10.2%).
[0222] Methyl 3-methyl-5-(3-methylphenyl)-4-isoxazole carboxylate (183 mg) was dissolved in tetrahydrofuran/distilled water=4/1 (2 ml). Lithium hydroxide (66.5 mg) was added at room temperature, and the mixture was stirred at that temperature for 20 hours. After the completion of the reaction, 5%-aqueous hydrochloric acid was added to acidify the system, and the reaction product was extracted by liquid separation using chloroform and washed with saturated aqueous solution of sodium chloride. The product was dried over sodium sulfate to concentrate and the residue was dried using a vacuum pump. Thus, a useful intermidiate, i.e., 3-methyl-5-(3-methylphenyl)-4-isoxazole carboxylic acid (169 mg, yield 98%) was obtained.
[0223] 3-Methyl-5-(3-methylphenyl)-4-isoxazole carboxylic acid (80 mg) was dissolved in anhydrous toluene (2.0 ml). Subsequently, diphenylphosphoryl azide (95 μl) and triethylamine (62 μl) were added at room temperature and the mixture was stirred at 120° C. for 1 hour. After the product was allowed to stand at room temperature, 1-phenyl-ethanol (67 μl) was added and the mixture was stirred again at 120° C. for 2 hours. After the completion of the reaction, the reaction product was allowed to cool at room temperature, distilled water was added thereto, and the product was extracted by liquid separation using chloroform and washed with saturated aqueous solution of sodium chloride. The product was dried over sodium sulfate to concentrate and the residue was purified by silica gel column chromatography using a hexane-acetone elution system. Thus, the title compound 27 (65.9 mg, yield 53.3%) was obtained.
[0224] [0224] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.60 (9H, m), 5.89 (2H, bs), 2.36 (3H, s), 2.23 (3H, s), 1.50-1.65 (3H, m)
[0225] Mass spectrometry (ESI-MS): 337 (M + +1)
Example 28
[0226] Synthesis of Compound 28: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(3-methylphenyl)-4-isoxazolyl]carbamate
[0227] The title compound 28 was obtained in the same manner as used in Example 27.
[0228] [0228] 1 H-NMR (CDCl 3 , 400 MHz): δ7.23-7.65 (8H, m), 6.18-6.28 (1H, m), 5.98 (1H, bs), 2.38 (3H, s), 2.26 (3H, s), 1.50-1.57 (3H, m)
[0229] Mass spectrometry (ESI-MS): 371 (M + +1)
Example 29
[0230] Synthesis of Compound 29: 1-Phenylethyl N-[5-(3-fluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0231] The title compound 29 was obtained in the same manner as used in Example 27.
[0232] [0232] 1 H-NMR (CDCl 3 , 400 MHz): δ7.10-7.60 (9H, m), 6.22 (1H, q, J=6.5 Hz), 6.03 (1H, bs), 2.25 (3H, s), 1.50-1.70 (3H, m)
[0233] Mass spectrometry (ESI-MS): 341 (M + +1)
Example 30
[0234] Synthesis of Compound 30: 1-(2-Chlorophenyl)ethyl N-[5-(3-fluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0235] The title compound 30 was obtained in the same manner as used in Example 27.
[0236] [0236] 1 H-NMR (CDCl 3 , 400 MHz): δ7.09-7.58 (8H, m), 5.87 (1H, q, J=6.6 Hz), 2.22 (3H, s), 1.50-1.69 (3H, m)
[0237] Mass spectrometry (ESI-MS): 375 (M + +1)
Example 31
[0238] Synthesis of Compound 31: 1-Phenylethyl N-[5-(2-furyl)-3-methyl-4-isoxazolyl]carbamate
[0239] The title compound 31 was obtained in the same manner as used in Example 27.
[0240] [0240] 1 H-NMR (CDCl 3 , 400 MHz): δ7.50 (1H, s), 7.23-7.40 (5H, m), 6.82 (1H, s), 6.45-6.60 (1H, m), 6.26 (1H, bs), 5.87 (1H, q, J=6.6 Hz), 2.24 (3H, s), 1.50-1.70 (3H, m)
[0241] Mass spectrometry (ESI-MS): 313 (M + +1)
Example 32
[0242] Synthesis of Compound 32: 1-(2-Chlorophenyl)ethyl N-[5-(2-furyl)-3-methyl-4-isoxazolyl] carbamate
[0243] The title compound 32 was obtained in the same manner as used in Example 27.
[0244] [0244] 1 H-NMR (CDCl 3 , 400 MHz): δ7.53-7.57 (1H, m), 7.20-7.40 (4H, m), 6.86 (1H, s), 6.53 (1H, dd, J=1.7 Hz, J=3.4 Hz), 6.21 (1H, q, J=6.5 Hz), 2.27 (3H, s), 1.50-1.60 (3H, m)
[0245] Mass spectrometry (ESI-MS): 347 (M + +1)
Example 33
[0246] Synthesis of Compound 33: (1R)-1-(2-Bromophenyl)ethyl N-[5-(3-fluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0247] The title compound 33 was obtained in the same manner as used in Example 27.
[0248] [0248] 1 H-NMR (CDCl 3 , 400 MHz): δ7.06-7.60 (8H, m), 6.16 (1H, q, J=6.5 Hz), 6.08 (1H, bs), 2.25 (3H, s), 1.50-1.70 (3H, m)
[0249] Mass spectrometry (ESI-MS): 419, 421 (M + +1)
Example 34
[0250] Synthesis of Compound 34: 1-(2-Fluorophenyl)ethyl N-[5-(3-fluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0251] The title compound 34 was obtained in the same manner as used in Example 27.
[0252] [0252] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.60 (8H, m), 6.00-6.18 (2H, m), 2.24 (3H, s), 1.50-1.70 (3H, m)
[0253] Mass spectrometry (ESI-MS): 359 (M + +1)
Example 35
[0254] Synthesis of Compound 35: 1-Phenylethyl N-[5-[4-(trifluoromethoxy)phenyl]-3-methyl-4-isoxazolyl]carbamate
[0255] The title compound 35 was obtained in the same manner as used in Example 27.
[0256] [0256] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (9H, m), 5.85 (1H, q, J=6.6 Hz), 2.21 (3H, s), 1, 45-1.65 (3H, m)
[0257] Mass spectrometry (ESI-MS): 407 (M + +1)
Example 36
[0258] Synthesis of Compound 36: 1-(2-Chlorophenyl)ethyl N-[5-[4-(trifluoromethoxy)phenyl]-3-methyl-4-isoxazolyl]carbamate
[0259] The title compound 36 was obtained in the same manner as used in Example 27.
[0260] [0260] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (2H, bs), 6.80-7.50 (6H, m), 6.15 (1H, q, J=6.5 Hz), 5.90 (1H, bs), 2.19 (3H, s), 1.42-1.60 (3H, m)
[0261] Mass spectrometry (ESI-MS): 441 (M + +1)
Example 37
[0262] Synthesis of Compound 37: 1-Phenylethyl N-[3-methyl-5-(4-methylphenyl)-4-isoxazolyl]carbamate
[0263] The title compound 37 was obtained in the same manner as used in Example 27.
[0264] [0264] 1 H-NMR (CDCl 3 , 400 MHz): δ7.62 (2H, bs), 7.15-7.45 (7H, m), 5.80-5.92 (2H, m), 2.39 (3H, s), 2.21 (3H, s), 1.50-1.67 (3H, m)
[0265] Mass spectrometry (ESI-MS): 337 (M + +1)
Example 38
[0266] Synthesis of Compound 38: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(4-methylphenyl)-4-isoxazolyl] carbamate
[0267] The title compound 38 was obtained in the same manner as used in Example 27.
[0268] [0268] 1 H-NMR (CDCl 3 , 400 MHz): δ7.65 (2H, bs), 6.90-7.60 (6H, m), 6.21 (1H, q, J=6.4 Hz), 5.98 (1H, bs), 2.40 (3H, s), 2.24 (3H, s), 1.50-1.70 (3H, m)
[0269] Mass spectrometry (ESI-MS): 371 (M + +1)
Example 39
[0270] Synthesis of Compound 39: 1-(2-Chlorophenyl)ethyl N-[5-(3-chlorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0271] The title compound 39 was obtained in the same manner as used in Example 27.
[0272] [0272] 1 H-NMR (CDCl 3 , 400 MHz): δ7.71 (1H, s), 7.20-7.65 (7H, m), 6.16 (1H, q, J=6.6 Hz), 5.91 (1H, bs), 2.19 (3H, s), 1.40-1.60 (3H, m)
[0273] Mass spectrometry (ESI-MS): 391 (M + +1)
Example 40
[0274] Synthesis of Compound 40: 1-Phenylethyl N-[5-(4-fluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0275] The title compound 40 was obtained in the same manner as used in Example 27.
[0276] [0276] 1 H-NMR (CDCl 3 , 400 MHz): δ7.70 (2H, bs), 7.00-7.50 (7H, m), 5.80-5.95 (2H, m), 2.22 (3H, s) 1.50-1.65 (3H, m)
[0277] Mass spectrometry (ESI-MS): 341 (M + +1)
Example 41
[0278] Synthesis of Compound 41: 1-(2-Chlorophenyl)ethyl N-[5-(4-fluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0279] The title compound 41 was obtained in the same manner as used in Example 27.
[0280] [0280] 1 H-NMR (CDCl 3 , 400 MHz): δ7.75 (2H, bs), 6.80-7.60 (6H, m), 6.22 (1H, q, J=6.5 Hz), 5.96 (1H, bs), 2.25 (3H, s), 1.50-1.65 (3H, m)
[0281] Mass spectrometry (ESI-MS): 375 (M + +1)
Example 42
[0282] Synthesis of Compound 42: 1-Phenylethyl N-[5-(2-fluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0283] The title compound 42 was obtained in the same manner as used in Example 27.
[0284] [0284] 1 H-NMR (CDCl 3 , 400 MHz): δ7.64-7.70 (1H, m), 7.13-7.50 (8H, m), 6.18 (1H, bs), 5.82 (1H, q, J=6.6 Hz), 2.27 (3H, s), 1.56 (3H, bs)
[0285] Mass spectrometry (ESI-MS): 341 (M + +1)
Example 43
[0286] Synthesis of Compound 43: 1-(2-Chlorophenyl)ethyl N-[5-(2-fluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0287] The title compound 43 was obtained in the same manner as used in Example 27.
[0288] [0288] 1 H-NMR (CDCl 3 , 400 MHz): δ7.65-7.72 (1H, m), 7.15-7.50 (7H, m), 6.12-6.25 (2H, m), 2.29 (3H, s), 1.50-1.60 (3H, m)
[0289] Mass spectrometry (ESI-MS): 375 (M + +1)
Example 44
[0290] Synthesis of Compound 44: (1R)-1-(2-Bromophenyl)ethyl N-[3-methyl-5-[4-(trifluoromethoxy)phenyl]-4-isoxazolyl]carbamate
[0291] The title compound 44 was obtained in the same manner as used in Example 27.
[0292] [0292] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (2H, bs), 6.90-7.55 (6H, m), 6.10 (1H, q, J=6.6 Hz), 5.91 (1H, bs), 2.19 (3H, s), 1.40-1.60 (3H, m)
[0293] Mass spectrometry (ESI-MS): 485 (M + +1)
Example 45
[0294] Synthesis of Compound 45: 1-(2-Fluorophenyl)ethyl N-[3-methyl-5-[4-(trifluoromethoxy)phenyl]-4-isoxazolyl]carbamate
[0295] The title compound 45 was obtained in the same manner as used in Example 27.
[0296] [0296] 1 H-NMR (CDCl 3 , 400 MHz): δ7.65-7.80 (2H, m), 6.90-7.45 (6H, m), 6.06 (1H, q, J=6.7 Hz), 5.89 (1H, bs), 2.18 (3H, s), 1.43-1.65 (3H, m)
[0297] Mass spectrometry (ESI-MS): 425 (M + +1)
Example 46
[0298] Synthesis of Compound 46: 1-Phenylethyl N-[5-(4-cyanophenyl)-3-methyl-4-isoxazolyl]carbamate
[0299] The title compound 46 was obtained in the same manner as used in Example 27.
[0300] [0300] 1 H-NMR (CDCl 3 , 400 MHz): δ7.75-7.85 (2H, m), 7.63-7.68 (3H, m), 7.25-7.50 (4H, m), 5.99 (1H, bs), 5.86 (1H, q, J=6.6 Hz), 2.24 (3H, s), 1.50-1.67 (3H, m)
[0301] Mass spectrometry (ESI-MS): 348 (M + +1)
Example 47
[0302] Synthesis of Compound 47: 1-(2-Chlorophenyl)ethyl N-[5-(4-cyanophenyl)-3-methyl-4-isoxazolyl]carbamate
[0303] The title compound 47 was obtained in the same manner as used in Example 27.
[0304] [0304] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.95 (8H, m), 6.22 (1H, q, J=6.6 Hz), 6.02 (1H, bs), 2.27 (3H, s), 1.50-1.70 (3H, m)
[0305] Mass spectrometry (FD-MS): 381 (M + )
Example 48
[0306] Synthesis of Compound 48: (1R)-1-(2-Bromophenyl)ethyl N-[3-methyl-5-(4-methylphenyl)-4-isoxazolyl]carbamate
[0307] The title compound 48 was obtained in the same manner as used in Example 27.
[0308] H-NMR (CDCl 3 , 400 MHz): δ6.90-7.76 (8H, m), 6.13 (1H, q, J=6.6 Hz), 6.01 (1H, bs), 2.39 (3H, s), 2.23 (3H, s like), 1.53-1.72 (3H, m)
[0309] Mass spectrometry (ESI-MS): 415 (M + +1)
Example 49
[0310] Synthesis of Compound 49: 1-(2-Fluorophenyl)ethyl N-[3-methyl-5-(4-methylphenyl)-4-isoxazolyl]carbamate
[0311] The title compound 49 was obtained in the same manner as used in Example 27.
[0312] [0312] 1 H-NMR (CDCl 3 , 400 MHz): δ6.90-7.75 (8H, m), 6.15 (1H, q, J=6.4 Hz), 6.02 (1H, bs), 2.39 (3H, s), 2.24 (3H, s), 1.50-1.70 (3H, m)
[0313] Mass spectrometry (ESI-MS): 355 (M + +1)
Example 50
[0314] Synthesis of Compound 50: 1-(2-Chlorophenyl)ethyl N-[5-(4-methoxyphenyl)-3-methyl-4-isoxazolyl]carbamate
[0315] The title compound 50 was obtained in the same manner as used in Example 27.
[0316] [0316] 1 H-NMR (CDCl 3 , 400 MHz): δ7.68 (2H, bs), 7.20-7.55 (4H, m), 6.92 (2H, d, J=9.0 Hz), 5.95 (1H, bs), 3.83 (3H, s), 2.21 (3H, s), 1.35-1.65 (3H, m)
[0317] Mass spectrometry (ESI-MS): 387, 389 (M + +1)
Example 51
[0318] Synthesis of Compound 51: 1-(2-Chlorophenyl)ethyl N-[5-(2-bromophenyl)-3-methyl-4-isoxazolyl]carbamate
[0319] The title compound 51 was obtained in the same manner as used in Example 27.
[0320] [0320] 1 H-NMR (CDCl 3 , 400 MHz): δ7.65-7.70 (1H, m), 7.16-7.50 (7H, m), 6.12 (1H, q, J=6.5 Hz), 6.00-6.25 (1H, m), 2.28 (3H, s), 1.52 (3H, bs)
[0321] Mass spectrometry (ESI-MS): 435, 437 (M + +1)
Example 52
[0322] Synthesis Of Compound 52: 1-(2-Chlorophenyl)ethyl N-[5-(1,3-benzodioxol-5-yl)-3-methyl-4-isoxazolyl]carbamate
[0323] The title compound 52 was obtained in the same manner as used in Example 27.
[0324] [0324] 1 H-NMR (CDCl 3 , 400 MHz): δ6.90-7.60 (5H, m), 6.84 (1H, d, J=8.3 Hz), 6.20 (1H, q, J=6.5 Hz), 5.98-6.08 (3H, m), 2.22 (3H, s), 1.35-1.70 (3H, m)
[0325] Mass spectrometry (ESI-MS): 401 (M + +1)
Example 53
[0326] Synthesis of Compound 53: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-[3-(trifluoromethoxy)phenyl]-4-isoxazolyl]carbamate
[0327] The title compound 53 was obtained in the same manner as used in Example 27.
[0328] [0328] 1 H-NMR (CDCl 3 , 400 MHz): δ7.55-7.68 (2H, m), 7.18-7.50 (6H, m), 6.16 (1H, q, J=6.5 Hz), 5.92 (1H, bs), 2.19 (3H, s), 1.40-1.60 (3H, m)
[0329] Mass spectrometry (ESI-MS): 441 (M + +1)
Example 54
[0330] Synthesis of Compound 54: 1-Phenylethyl N-[3-methyl-5-(4-nitrophenyl)-4-isoxazolyl]carbamate
[0331] The title compound 54 was obtained in the same manner as used in Example 27.
[0332] [0332] 1 H-NMR (CDCl 3 , 400 MHz): δ8.13-8.18 (2H, m), 7.75-7.85 (2H, m), 7.00-8.00 (5H, m), 5.92 (1H, bs), 5.80 (1H, q, J=6.6 Hz), 2.19 (3H, s), 1.40-1.65 (3H, m)
[0333] Mass spectrometry (ESI-MS): 368 (M + +1)
Example 55
[0334] Synthesis of Compound 55: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(4-nitrophenyl)-4-isoxazolyl]carbamate
[0335] The title compound 55 was obtained in the same manner as used in Example 27.
[0336] [0336] 1 H-NMR (CDCl 3 , 400 MHz): δ8.18-8.23 (2H, m), 7.80-7.90 (2H, m), 7.15-7.50 (4H, m), 6.16 (1H, q, J=6.6 Hz), 2.22 (3H, s), 1.40-1.62 (3H, m)
[0337] Mass spectrometry (ESI-MS): 402 (M + +1)
Example 56
[0338] Synthesis of Compound 56: 1-Phenylethyl N-[3-methyl-5-(2-thienyl)-4-isoxazolyl]carbamate
[0339] The title compound 56 was obtained in the same manner as used in Example 27.
[0340] [0340] 1 H-NMR (CDCl 3 , 400 MHz): δ7.08-7.60 (8H, m), 5.65-6.00 (2H, m), 2.22 (3H, s), 1.52-1.70 (3H, m)
[0341] Mass spectrometry (ESI-MS): 329 (M + +1)
Example 57
[0342] Synthesis of Compound 57: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(2-thienyl)-4-isoxazolyl]carbamate
[0343] The title compound 57 was obtained in the same manner as used in Example 27.
[0344] [0344] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.65 (7H, m), 6.22 (1H, q, J=6.6 Hz), 5.98 (1H, bs), 2.25 (3H, s), 1.50-1.70 (3H, m)
[0345] Mass spectrometry (ESI-MS): 363 (M + +1)
Example 58
[0346] Synthesis of Compound 58: 1-Phenylethyl N-[3-methyl-5-(3-nitrophenyl)-4-isoxazolyl]carbamate
[0347] The title compound 58 was obtained in the same manner as used in Example 27.
[0348] [0348] 1 H-NMR (CDCl 3 , 400 MHz): δ8.59-8.62 (1H, m), 8.20-8.27 (1H, m), 8.00-8.05 (1H, m), 7.58 (1H, dd, J=8.1 Hz), 7.20-7.40 (5H, m), 6.00 (1H, bs), 5.85 (1H, q, J=6.6 Hz), 2.24 (3H, s), 1.45-1.70 (3H, m)
[0349] Mass spectrometry (ESI-MS): 368 (M + +1)
Example 59
[0350] Synthesis of Compound 59: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(3-nitrophenyl)-4-isoxazolyl]carbamate
[0351] The title compound 59 was obtained in the same manner as used in Example 27.
[0352] [0352] 1 H-NMR (CDCl 3 , 400 MHz): δ8.58 (1H, dd, J=2.0 Hz), 8.18-8.23 (1H, m), 8.00-8.05 (1H, m), 7.56 (1H, dd, J=8.0 Hz), 7.15-7.35 (4H, m), 6.16 (1H, q, J=6.6 Hz), 2.22 (3H, s), 1.30-1.67 (3H, m)
[0353] Mass spectrometry (ESI-MS): 402 (M + +1)
Example 60
[0354] Synthesis of Compound 60: 1-(2-Chlorophenyl)ethyl N-[5-(2,4-difluorophenyl)-3-methyl-4-isoxazolyl]carbamate
[0355] The title compound 60 was obtained in the same manner as used in Example 27.
[0356] [0356] 1 H-NMR (CDCl 3 , 400 MHz): δ7.61-7.69 (1H, m), 7.20-7.50 (4H, m), 6.86-7.03 (2H, m), 6.14 (1H, q, J=6.6 Hz), 6.05-6.20 (1H, m), 2.26 (3H, s), 1.45-1.65 (3H, m)
[0357] Mass spectrometry (ESI-MS): 393 (M + +1)
Example 61
[0358] Synthesis of Compound 61: 1-Phenylethyl N-[3-methyl-5-(4-pyridyl)-4-isoxazolyl]carbamate
[0359] The title compound 61 was obtained in the same manner as used in Example 27.
[0360] [0360] 1 H-NMR (CDCl 3 , 400 MHz): δ8.66 (2H, d, J=5.2 Hz), 7.57 (2H, bs), 7.25-7.50 (5H, m), 6.05 (1H, bs), 5.87 (1H, q, J=6.5 Hz), 2, 25 (3H, s), 1.50-1.70 (3H, m)
[0361] Mass spectrometry (ESI-MS): 324 (M + +1)
Example 62
[0362] Synthesis of Compound 62: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(4-pyridyl)-4-isoxazolyl]carbamate
[0363] The title compound 62 was obtained in the same manner as used in Example 27.
[0364] [0364] 1 H-NMR (CDCl 3 , 400 MHz): δ8.69 (2H, d, J=5.6 Hz), 7.25-7.70 (6H, m), 6.23 (1H, q, J=6.5 Hz), 6.14 (1H, bs), 2.28 (3H, s), 1.55-1.70 (3H, m)
[0365] Mass spectrometry (ESI-MS): 358, 360 (M + +1)
Example 63
[0366] Synthesis of Compound 63: 1-(2-Chlorophenyl)ethyl N-[5-(6-chloro-3-pyridyl)-3-methyl-4-isoxazolyl]carbamate
[0367] The title compound 63 was obtained in the same manner as used in Example 27.
[0368] [0368] 1 H-NMR (CDCl 3 , 400 MHz): δ8.79 (1H, s), 7.92-8.00 (1H, m), 7.25-7.50 (5H, m), 6.19 (1H, q, J=6.5 Hz), 5.99 (1H, bs), 2.25 (3H, s), 1.45-1.65 (3H, m)
[0369] Mass spectrometry (ESI-MS): 392, 394 (M + +1)
Example 64
[0370] Synthesis of Compound 64: 1-Phenylethyl N-[5-(4-butylphenyl)-3-methyl-4-isoxazolyl]carbamate
[0371] The title compound 64 was obtained in the same manner as used in Example 27.
[0372] [0372] 1 H-NMR (CDCl 3 , 400 MHz): δ7.18-7.70 (9H, m), 5.65-6.00 (2H, m), 2.62 (2H, t, J=7.7 Hz), 2.19 (3H, s), 1.29-1.70 (7H, m), 0.92 (3H, t, J=7.3 Hz)
[0373] Mass spectrometry (ESI-MS): 379 (M + +1)
Example 65
[0374] Synthesis of Compound 65: 1-(2-Chlorophenyl)ethyl N-[5-(4-butylphenyl)-3-methyl-4-isoxazolyl]carbamate
[0375] The title compound 65 was obtained in the same manner as used in Example 27.
[0376] [0376] 1 H-NMR (CDCl 3 , 400 MHz): δ6.90-7.70 (8H, m), 6.15 (1H, q, J=6.4 Hz), 5.91 (1H, bs), 2.58 (2H, t, J=7.7 Hz), 2.18 (3H, s), 1.20-1.60 (7H, m), 0.87 (3H, t, J=7.3 Hz)
[0377] Mass spectrometry (ESI-MS): 413, 415 (M + +1)
Example 66
[0378] Synthesis of Compound 66: 1-Phenylethyl N-[3-methyl-5-(3-methyl-2-thienyl)-4-isoxazolyl]carbamate
[0379] The title compound 66 was obtained in the same manner as used in Example 27.
[0380] [0380] 1 H-NMR (CDCl 3 , 400 MHz): δ7.25-7.50 (6H, m), 6.72-6.78 (1H, m), 5.80-5.95 (1H, m), 2.50 (3H, s like), 2.20 (3H, s), 1.5-1.68 (3H, m)
[0381] Mass spectrometry (ESI-MS): 343 (M + +1)
Example 67
[0382] Synthesis of Compound 67: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(3-methyl-2-thienyl)-4-isoxazolyl]carbamate
[0383] The title compound 67 was obtained in the same manner as used in Example 27.
[0384] [0384] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.65 (5H, m), 6.75-6.80 (1H, m), 6.22 (1H, q, J=6.5 Hz), 5.94 (1H, bs), 2.58 (3H, s like), 2.23 (3H, s), 1.55-1.65 (3H, m)
[0385] Mass spectrometry (ESI-MS): 377, 379 (M + +1)
Example 68
[0386] Synthesis of Compound 68: 1-(2-Chlorophenyl)ethyl N-[5-(3-furyl)-3-methyl-4-isoxazolyl]carbamate
[0387] The title compound 68 was obtained in the same manner as used in Example 27.
[0388] [0388] 1 H-NMR (CDCl 3 , 400 MHz): δ7.76 (1H, bs), 7.10-7.50 (5H, m), 6.66 (1H, bs), 6.15 (1H, q, J=6.6 Hz), 5.86 (1H, bs), 2.16 (3H, s), 1.54 (3H, bs) Mass spectrometry (ESI-MS): 347 (M + +1)
Example 69
[0389] Synthesis of Compound 69: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(5-methyl-2-thienyl)-4-isoxazolyl] carbamate
[0390] The title compound 69 was obtained in the same manner as used in Example 27.
[0391] [0391] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.55 (5H, m), 6.93 (1H, d, J=5.1 Hz), 6.21 (1H, q, J=6.5 Hz), 5.95 (1H, s), 2.49 (3H, s), 2.25 (3H, s), 1.50-1.60 (3H, m)
[0392] Mass spectrometry (ESI-MS): 377 (M + +1)
Example 70
[0393] Synthesis of Compound 70: 1-(2-Chlorophenyl)ethyl N-[5-[3-(chloromethyl)phenyl]-3-methyl-4-isoxazolyl]carbamate
[0394] The title compound 70 was obtained in the same manner as used in Example 27.
[0395] [0395] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.85 (8H, m), 6.23 (1H, q, J=6.8 Hz), 6.04 (1H, bs), 4.58 (2H, s), 2.26 (3H, s), 1.50-1.70 (3H, m)
[0396] Mass spectrometry (ESI-MS): 405, 407 (M + +1)
Example 71
[0397] Synthesis of Compound 71: 1-(2-Chlorophenyl)ethyl N-[5-(2-chloro-4-pyridyl)-3-methyl-4-isoxazolyl]carbamate
[0398] The title compound 71 was obtained in the same manner as used in Example 27.
[0399] [0399] 1 H-NMR (CDCl 3 , 400 MHz): δ8.39 (1H, d, J=5.4 Hz), 7.20-7.55 (5H, m), 7.62 (1H, s), 6.16 (1H, q, J=6.6 Hz), 6.00 (1H, bs), 2.21 (3H, s), 1.35-1.65 (3H, m)
[0400] Mass spectrometry (ESI-MS): 392, 394 (M + +1)
Example 72
[0401] Synthesis of Compound 72: 1-(2-Chlorophenyl)ethyl N-[5-(3-phenyl-5-methyl-4-isoxazolyl)-3-methyl-4-isoxazolyl]carbamate
[0402] The title compound 72 was obtained in the same manner as used in Example 27.
[0403] [0403] 1 H-NMR (CDCl 3 , 400 MHz): δ87.10-7.50 (9H, m), 5.85-5.95 (1H, m), 5.17 (1H, bs), 2.44 (3H, s), 2.16 (3H, s), 1.36 (3H, d, J=6.3 Hz)
[0404] Mass spectrometry (ESI-MS): 438, 439 (M + +1)
Example 73
[0405] Synthesis of Compound 73: 1-(2-Chlorophenyl)ethyl N-[5-(5-bromo-2-furyl)-3-methyl-4-isoxazolyl]carbamate
[0406] The title compound 73 was obtained in the same manner as used in Example 27.
[0407] [0407] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.55 (4H, m), 6.75-6.80 (1H, m), 6.43 (1H, d, J=3.6 Hz), 6.20 (1H, q, J=6.5 Hz), 2.24 (3H, s), 1.45-1.70 (3H, m)
[0408] Mass spectrometry (ESI-MS): 427 (M + +1)
Example 74
[0409] Synthesis of Compound 74: 1-(2-Chlorophenyl)ethyl N-[5-[4-(chloromethyl)phenyl]-3-methyl-4-isoxazolyl]carbamate
[0410] The title compound 74 was obtained in the same manner as used in Example 27.
[0411] [0411] 1 H-NMR (CDCl 3 , 400 MHz): δ7.69 (2H, bs), 6.75-7.50 (6H, m), 6.15 (1H, q, J=6.4 Hz), 5.95 (1H, bs), 4.53 (2H, s), 2.18 (3H, s), 1.45-1.62 (3H, m)
[0412] Mass spectrometry (ESI-MS): 405 (M + +1)
Example 75
[0413] Synthesis of Compound 75: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(3-thienyl)-4-isoxazolyl]carbamate
[0414] The title compound 75 was obtained in the same manner as used in Example 27.
[0415] [0415] 1 H-NMR (CDCl 3 , 400 MHz): δ7.75 (1H, bs), 7.00-7.60 (6H, m), 6.22 (1H, q, J=6.4 Hz), 5.98 (1H, bs), 2.24 (3H, s), 1.50-1.70 (3H, m)
[0416] Mass spectrometry (ESI-MS): 361 (M + +1)
Example 76
[0417] Synthesis of Compound 76: 1-(2-Chlorophenyl)ethyl N-(3-ethyl-5-phenyl-4-isoxazolyl)carbamate
[0418] The title compound 76 was obtained in the same manner as used in Example 27.
[0419] [0419] 1 H-NMR (CDCl 3 , 400 MHz): δ6.75-7.85 (9H, m), 6.12-6.25 (1H, m), 5.97 (1H, bs), 2.64 (2H, m), 1.52-1.65 (2H, m), 1.28 (3H, t, J=7.6 Hz)
[0420] Mass spectrometry (ESI-MS): 371 (M + +1)
Example 77
[0421] Synthesis of Compound 77: 1-(2-Chlorophenyl)ethyl N-[5-(4-cyanophenyl)-3-ethyl-4-isoxazolyl]carbamate
[0422] The title compound 77 was obtained in the same manner as used in Example 27.
[0423] [0423] 1 H-NMR (CDCl 3 , 400 MHz): δ7.85 (2H, bs), 7.69 (H, d, J=8.3 Hz), 7.25-7.55 (4H, m), 6.21 (1H, q, J=6.6 Hz), 6.01 (1H, bs), 2.67 (2H, q, J=7.6 Hz), 1.31 (3H, t, J=7.6 Hz)
[0424] Mass spectrometry (ESI-MS): 394, 396 (M + −1)
Example 78
[0425] Synthesis of Compound 78: 1-(2-Chlorophenyl)ethyl N-[3-(methoxymethyl)-5-phenyl-4-isoxazolyl]carbamate
[0426] The title compound 78 was obtained in the same manner as used in Example 27.
[0427] [0427] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.78 (9H, m), 6.05-6.19 (1H, m), 4.43-4.60 (2H, m), 3.31 (3H, s), 1.40-1.50 (3H, m)
[0428] Mass spectrometry (ESI-MS): 387, 389 (M + +1)
Example 79
[0429] Synthesis of Compound 79: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-[4-(phenoxymethyl)phenyl]-4-isoxazolyl]carbamate
[0430] The title compound 79 was obtained in the same manner as used in Example 27.
[0431] [0431] 1 H-NMR (CDCl 3 , 400 MHz): δ7.76 (2H, bs), 7.43-7.55 (3H, m), 7.25-7.43 (6H, m), 6.95-7.02 (2H, m), 6.22 (1H, q, J=6.6 Hz), 6.00 (1H, bs), 5.11 (1H, s), 4.60 (1H, s), 2.56 (3H, s), 1.50-1.70 (3H, m)
[0432] Mass spectrometry (ESI-MS): 463 (M + +1)
Example 80
[0433] Synthesis of Compound 80: 2,2,2-Trifluoro-1-phenylethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0434] The title compound 80 was obtained in the same manner as used in Example 1.
[0435] [0435] 1 H-NMR (CDCl 3 , 400 MHz): δ7.18-7.60 (10H, m), 6.00-6.15 (2H, m), 2.33 (3H, s)
[0436] Mass spectrometry (ESI-MS): 375 (M + +1)
Example 81
[0437] Synthesis of Compound 81: 1-Phenylallyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0438] The title compound 81 was obtained in the same manner as used in Example 1.
[0439] [0439] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.75 (10H, m), 5.00-6.30 (4H, m), 2.37 (3H, s)
[0440] Mass spectrometry (ESI-MS): 335 (M + +1)
Example 82
[0441] Synthesis of Compound 82: 1-(2-Chlorophenyl)ethyl N-[5-(4-[[(4-fluorobenzyl)oxy]methyl]phenyl)-3-methyl-4-isoxazolyl]carbamate
[0442] The title compound 82 was obtained in the same manner as used in Example 27.
[0443] [0443] 1 H-NMR (CDCl 3 , 400 MHz): δ6.90-7.80 (12H, m), 6.15-6.25 (1H, m), 5.98 (1H, bs), 4.50-4.58 (4H, m), 2.13-2.17 (3H, s), 1.20-1.70 (3H, m) Mass spectrometry (ESI-MS): 495 (M + +1)
Example 83
[0444] Synthesis of Compound 83: 1-(2-Chlorophenyl)ethyl N-[5-(4-[[(2,6-difluorobenzyl)oxy]methyl]phenyl)-3-methyl-4-isoxazolyl]carbamate
[0445] The title compound 83 was obtained in the same manner as used in Example 27.
[0446] [0446] 1 H-NMR (CDCl 3 , 400 MHz): δ6.85-7.80 (11H, m), 6.19 (1H, q, J=6.6 Hz), 4.65 (2H, s), 4.59 (2H, s), 2.23 (3H, s), 1.47-1.65 (3H, m)
[0447] Mass spectrometry (ESI-MS): 513 (M + +1)
Example 84
[0448] Synthesis of Compound 84: 1-(2-Chlorophenyl)ethyl N-(5-[4-[(2-furylmethoxy)methyl]phenyl]-3-methyl-4-isoxazolyl)carbamate
[0449] The title compound 84 was obtained in the same manner as used in Example 27.
[0450] [0450] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.80 (9H, m), 6.31-6.36 (2H, m), 6.20 (1H, q, J=6.5 Hz), 5.98 (1H, bs), 4.56 (2H, s), 4.50 (2H, s), 2.23 (3H, s), 1.48-1.65 (3H, m)
[0451] Mass spectrometry (ESI-MS): 467 (M + +1)
Example 85
[0452] Synthesis of Compound 85: 1-(2-Chlorophenyl)ethyl N-(5-[4-[(3-furylmethoxy)methyl]phenyl]-3-methyl-4-isoxazolyl)carbamate
[0453] The title compound 85 was obtained in the same manner as used in Example 27.
[0454] [0454] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.80 (10H, m), 6.43 (1H, s), 6.20 (1H, q, J=6.5 Hz), 4.54 (3H, s), 4.43 (3H, s), 2.23 (3H, s), 1.45-1.70 (3H, m)
[0455] Mass spectrometry (ESI-MS): 467 (M + +1)
Example 86
[0456] Synthesis of Compound 86: 2,2,2-Trifluoro-1-phenylethyl N-[5-(4-cyanophenyl)-3-methyl-4-isoxazolyl]carbamate
[0457] The title compound 86 was obtained in the same manner as used in Example 27.
[0458] [0458] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (9H, m), 6.22 (1H, bs), 6.06 (1H, q, J=6.7 Hz), 2.20 (3H, s)
[0459] Mass spectrometry (ESI-MS): 402 (M + +1)
Example 87
[0460] Synthesis of Compound 87: 1-(2-Chlorophenyl)ethyl N-[5-[4-(methoxymethyl)phenyl]-3-methyl-4-isoxazolyl]carbamate
[0461] The title compound 87 was obtained in the same manner as used in Example 27.
[0462] [0462] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.75 (8H, m), 6.15 (1H, q, J=6.5 Hz), 5.93 (1H, bs), 4.43 (2H, s), 3.35 (3H, s), 2.18 (3H, s), 1.30-1.60 (3H, m)
[0463] Mass spectrometry (ESI-MS): 401 (M + +1)
Example 88
[0464] Synthesis of Compound 88: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-[4-(morpholinomethyl)phenyl]-4-isoxazolyl]carbamate
[0465] The title compound 88 was obtained in the same manner as used in Example 27.
[0466] [0466] 1 H-NMR (CDCl 3 , 400 MHz): δ6.98-7.80 (8H, m), 6.00-6.25 (2H, m), 3.71 (4H, t, J=4.4 Hz), 3.52 (2H, s), 2.41-2.47 (2H, m), 2.24 (3H, s), 1.35-1.70 (3H, m)
[0467] Mass spectrometry (ESI-MS): 454 (M + +1)
Example 89
[0468] Synthesis of Compound 89: 1-(2-Chlorophenyl)ethyl N-(5-[4-[(2,6-dimethylmorpholino)methyl]phenyl]-3-methyl-4-isoxazolyl)carbamate
[0469] The title compound 89 was obtained in the same manner as used in Example 27.
[0470] [0470] 1 H-NMR (CDCl 3 , 400 MHz): δ6.95-7.80 (8H, m), 5.95-6.25 (2H, m), 3.64-3.74 (2H, m), 3.49 (2H, s), 2.64-2.72 (2H, m), 2.24 (3H, s), 1.55-1.82 (5H, m), 1.13 (6H, d, J=6.4 Hz)
[0471] Mass spectrometry (ESI-MS): 484 (M + +1)
Example 90
[0472] Synthesis of Compound 90: 1-(2-Chlorophenyl)ethyl N-(3-methyl-5-[4-[([2-(2-pyridyl)ethyl]amino)methyl]phenyl]-4-isoxazolyl)carbamate
[0473] The title compound 90 was obtained in the same manner as used in Example 27.
[0474] [0474] 1 H-NMR (CDCl 3 , 400 MHz): δ8.49-8.55 (1H, m), 6.95-7.80 (11H, m), 6.50 (1H, bs), 6.21 (1H, q, J=6.3 Hz), 3.85 (2H, s), 2.97-3.10 (4H, m), 2.23 (3H, s), 1.62 (3H, bs)
[0475] Mass spectrometry (ESI-MS): 491, 493 (M + +1)
Example 91
[0476] Synthesis of Compound 91: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(4-[[(tetrahydro-2-furanylmethyl)amino]methyl]phenyl)-4-isoxazolyl]-carbamate
[0477] The title compound 91 was obtained in the same manner as used in Example 27.
[0478] [0478] 1 H-NMR (CDCl 3 , 400 MHz): δ6.95-7.80 (8H, m), 6.53 (1H, bs), 6.21 (1H, q, J=6.2 Hz), 3.99-4.07 (1H, m), 3.80-3.87 (3H, m), 3.70-3.78 (1H, m), 2.59-2.73 (2H, m), 2.23 (3H, s), 1.83-2.00 (4H, m), 1.35-1.75 (3H, m)
[0479] Mass spectrometry (ESI-MS): 470, 472 (M + +1)
Example 92
[0480] Synthesis of Compound 92: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(4-[[(2-pyridylmethyl)amino]methyl]phenyl)-4-isoxazolyl]carbamate
[0481] The title compound 92 was obtained in the same manner as used in Example 27.
[0482] [0482] 1 H-NMR (CDCl 3 , 400 MHz): δ8.54-8.58 (1H, m), 6.90-7.75 (11H, m), 6.64 (1H, bs), 6.21 (1H, q, J=6.4 Hz), 3.91 (2H, s), 3.86 (2H, s), 2.22 (3H, s), 1.30-1.70 (3H, m)
[0483] Mass spectrometry (ESI-MS): 477, 479 (M + +1)
Example 93
[0484] Synthesis of Compound 93: 1-(2-Chlorophenyl)ethyl N-[5-(4-[[(2-furylmethyl)amino]methyl]phenyl)-3-methyl-4-isoxazolyl]carbamate
[0485] The title compound 93 was obtained in the same manner as used in Example 27.
[0486] [0486] 1 H-NMR (CDCl 3 , 400 MHz): δ6.95-7.80 (8H, m), 5.98-6.35 (4H, m), 3.81 (2H, s), 3.79 (2H, s), 2.24 (3H, s), 1.30-1.75 (3H, m)
[0487] Mass spectrometry (ESI-MS): 466, 468 (M + +1)
Example 94
[0488] Synthesis of Compound 94: 2-Cyclohexyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0489] The title compound 94 was obtained in the same manner as used in Example 1.
[0490] [0490] 1 H-NMR (CDCl 3 , 400 MHz): 7.60 (2H, m), 7.36 (3H, m), 2.34 (3H, s), 1.59 (9H, m)
[0491] Mass spectrometry (FD-MS): 298 (M + )
Example 95
[0492] Synthesis of Compound 95: 2-Methylphenethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0493] The title compound 95 was obtained in the same manner as used in Example 1.
[0494] [0494] 1 H-NMR (CDCl 3 , 400 MHz): 7.59 (2H, dd, J=4.17 Hz, J=5.61 Hz), 7.38 (2H, dd, J=3.42 Hz, J=5.61 Hz), 7.09 (5H, m), 3.78 (2H, t, J=6.83 Hz), 2.83 (2H, t, J=6.83 Hz), 2.34 (3H, bs), 2.27 (3H, s)
[0495] Mass spectrometry (FD-MS): 336 (M + )
Example 96
[0496] Synthesis of Compound 96: Phenethyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0497] The title compound 96 was obtained in the same manner as used in Example 1.
[0498] H-NMR (CDCl 3 , 400 MHz): 7.37 (2H, m), 7.25 (2H, m), 7.18 (6H, m), 3.80 (2H, t, J=6.59 Hz), 2.81 (2H, t, J=6.59 Hz), 2.32 (3H, s), 2.18 (3H, bs)
[0499] Mass spectrometry (FD-MS): 322 (M + )
Example 97
[0500] Synthesis of Compound 97: 2,3-Dihydro-1H-1-indenyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0501] The title compound 97 was obtained in the same manner as used in Example 1.
[0502] Mass spectrometry (FD-MS): 334 (M + )
Example 98
[0503] Synthesis of Compound 98: 1,2,3,4-Tetrahydro-2-naphthalenyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0504] The title compound 98 was obtained in the same manner as used in Example 1.
[0505] Mass spectrometry (FD-MS): 348 (M + )
Example 99
[0506] Synthesis of Compound 99: Pentyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0507] The title compound 99 was obtained in the same manner as used in Example 1.
[0508] Mass spectrometry (FD-MS): 288 (M + )
Example 100
[0509] Synthesis of Compound 100: Isopentyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0510] The title compound 100 was obtained in the same manner as used in Example 1.
[0511] [0511] 1 H-NMR (CDCl 3 , 400 MHz): δ7.61 (2H, bs), 7.39 (3H, m), 4.11 (2H, m), 3.36 (3H, s), 1.49 (3H, m), 0.83 (6H, bs)
[0512] Mass spectrometry (FD-MS): 288 (M + )
Example 101
[0513] Synthesis of Compound 101: 1-Methylpentyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0514] The title compound 101 was obtained in the same manner as used in Example 1.
[0515] [0515] 1 H-NMR (CDCl 3 , 400 MHz): δ7.59 (2H, bs), 7.36 (3H, m), 4.65 (1H, m), 2.33 (3H, s), 1.21 (8H, m), 0.77 (4H, m)
[0516] Mass spectrometry (FD-MS): 302 (M + )
Example 102
[0517] Synthesis of Compound 102: 4-Pentenyl N-(5-methyl-3-phenyl-4-isoxazolyl)carbamate
[0518] The title compound 102 was obtained in the same manner as used in Example 1.
[0519] [0519] 1 H-NMR (CDCl 3 , 400 MHz): δ7.61 (2H, bs), 7.39 (3H, m), 4.93 (3H, m), 4.09 (2H, m), 2.36 (3H, s), 2.10 (2H, m), 1.73 (2H, m)
[0520] Mass spectrometry (FD-MS): 286 (M + )
Example 103
[0521] Synthesis of Compound 103: 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-[4-([2-(2-pyridyl)ethyl]amino) methyl)phenyl]-4-isoxazolyl)carbamate
[0522] Methyl 3-oxobutanoate (29.4 g) was dissolved in methanol (30.0 ml), and a 40%-methylamine-methanol solution (32.0 ml) was added dropwise at room temperature. The mixture was stirred for 1 hour. After the completion of the reaction, the reaction solution as such was concentrated, and then dried using a vacuum pump. Thus, methyl 3-(methylamino)-2-butenoate (31.8 g, yield 97%) was obtained. Subsequently, methyl 3-(methylamino)-2-butenoate (5.38 g) was dissolved in tetrahydrofuran (100 ml), and pyridine (5.0 ml) was added dropwise at room temperature. Under ice cooling, p-chloromethyl benzoyl chloride (8.0 g) was added dropwise and the mixture was stirred at room temperature for 4 hours. After the completion of the reaction, distilled water was added, and the product was extracted by liquid separation using ether and then washed with saturated aqueous solution of sodium chloride. The product was dried over sodium sulfate to concentrate and the residue was dried using a vacuum pump. Subsequently, the residue was dissolved in acetic acid (30.0 ml). Hydroxylamine hydrochloride (2.8 g) was added at room temperature, and the mixture was heated under reflux for 1 hour and 30 minutes. After the completion of the reaction, saturated aqueous solution of sodium hydrogencarbonate was added to neutralize the reaction system, and the product was extracted by liquid separation using ether. The resultant organic layer was washed with saturated solution of sodium chloride and dried over sodium sulfate to concentrate. The residue was purified through a column using a hexane-acetone elution system. Thus, methyl 5-[4-(chloromethyl)phenyl]-3-methyl-4-isoxazole carboxylate (5.42 g, yield 49.0%) was obtained.
[0523] Methyl 5-[4-(chloromethyl)phenyl]-3-methyl-4-isoxazole carboxylate (5.418 g) was dissolved in tetrahydrofuran/distilled water=2/1 (100.0 ml), lithium hydroxide (1.9 g) was added at room temperature, and the mixture was stirred at that temperature for 7 hours. After the completion of the reaction, a 5%-aqueous hydrochloric acid was added to acidify the system, the product was extracted by liquid separation using chloroform, and washed with saturated aqueous solution of sodium chloride. The product was dried over sodium sulfate to concentrate and the residue was dried using a vacuum pump. Thus, a useful intermediate, i.e., methyl 5-[4-(chloromethyl)phenyl]-3-methyl-4-isoxazole carboxylic acid (4.82 g, yield 94.0%), was obtained.
[0524] Methyl 5-[4-(chloromethyl)phenyl]-3-methyl-4-isoxazole carboxylic acid (4.82 g) was dissolved in anhydrous toluene (100.0 ml). Subsequently, diphenylphosphoryl azide (5.0 ml) and triethylamine (2.9 ml) were added at room temperature, and the mixture was stirred at 120° C. for 30 minutes. After the product was allowed to stand at room temperature, 1-(2-chlorophenyl)-1-ethanol (2.9 ml) was added and the mixture was stirred again at 120° C. for 2 hours. After the completion of the reaction, the reaction product was allowed to cool at room temperature, and distilled water was then added thereto, and the product was extracted by liquid separation using chloroform, and then washed with saturated aqueous solution of sodium chloride. The product was dried over sodium sulfate to concentrate and the residue was purified through a column using a hexane-acetone elution system. Thus, 1-(2-chlorophenyl)ethyl N-5-[4-chloromethyl]phenyl]-3-methyl-4-isoxazolylcarbamate (3.81 g, yield 49.0%) was obtained.
[0525] Subsequently, the resultant 1-(2-chlorophenyl)ethyl N-5-[4-chloromethyl]phenyl]-3-methyl-4-isoxazolylcarbamate (100 mg) was dissolved in methylene chloride (3.0 ml). Triethylamine (205.0 μl) and 2-(2-pyridyl)-1-ethanolamine (100 μl) were then added at room temperature, and the mixture was stirred at that temperature for 12 hours. After the completion of the reaction, distilled water was added thereto, and the reaction product was extracted by liquid separation using chloroform, and then washed with a saturated saline solution. The product was dried over sodium sulfate to concentrate and the residue was purified by column chromatography on silica gel. Thus, the title compound 103 (77 mg, 63.6%) was obtained.
[0526] [0526] 1 H-NMR (CDCl 3 , 400 MHz): δ8.51 (1H, d, J=4.9 Hz), 7.00-7.69 (11H, m), 6.50 (1H, bs), 6.21 (1H, q, J=6.3 Hz), 3.85 (2H, s), 2.99-3.01 (4H, m), 2.23 (3H, s), 1.40-1.70 (3H, m)
[0527] Mass spectrometry (ESI-MS): 491 (M + +1)
Examples 104 to 169
[0528] The following Compounds 104 to 169 were obtained in the same manner as used in Example 103. The structures of these compounds are shown in FIG. 1.
[0529] Compound 104
[0530] 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(4-{[(tetrahydro-2-furanylmethyl)amino]-methyl}phenyl)-4-isoxazolyl]carbamate
[0531] [0531] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (8H, m), 6.53 (1H, bs), 6.21 (1H, q, J=6.2 Hz), 3.99-4.06 (2H, m), 3.70-3.85 (3H, m), 2.60-2.73 (2H, m), 2.26 (3H, s), 1.50-2.00 (7H, m)
[0532] Mass spectrometry (ESI-MS): 470, 472 (M + +1)
[0533] Compound 105
[0534] 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(4-{[(2-pyridylmethyl)amino]methyl}-phenyl)-4-isoxazolyl]carbamate
[0535] [0535] 1 H-NMR (CDCl 3 , 400 MHz): δ8.53-8.58 (1H, m), 7.00-7.80 (11H, m), 6.64 (1H, bs), 6.21 (1H, q, J=6.4 Hz), 3.91 (2H, s), 3.86 (2H, s), 2.22 (3H, s), 1.30-1.70 (3H, m)
[0536] Mass spectrometry (ESI-MS): 477, 479 (M + +1)
[0537] Compound 106
[0538] 1-(2-Chlorophenyl)ethyl N-[5-(4-{[(2-furylmethyl)amino]methyl}phenyl)-3-methyl-4-isoxazolyl]carbamate
[0539] [0539] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (9H, m), 6.00-6.34 (4H, m), 3.81 (3H, s), 3.79 (3H, s), 2.24 (3H, s), 1.35-1.75 (3H, m)
[0540] Mass spectrometry (ESI-MS): 466, 468 (M + +1)
[0541] Compound 107
[0542] 1-(2-Chlorophenyl)ethyl N-[5-(4-{[(2-furylmethyl)sulfanyl]methyl}phenyl)-3-methyl-4-isoxazolyl]carbamate
[0543] [0543] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (1H, bs), 7.25-7.60 (8H, m), 6.32-6.34 (1H, m), 6.22 (1H, q, J=6.6 Hz), 6.15-6.18 (1H, m), 3.71 (2H, s), 3.59 (2H, s), 2.25 (3H, s), 1.35-1.70 (3H, m)
[0544] Mass spectrometry (ESI-MS): 483 (M + +1)
[0545] Compound 108
[0546] 1-(2-Chlorophenyl)ethyl N-(5-{4-[(ethylsulfanyl)methyl]phenyl}-3-methyl-4-isoxazolyl)carbamate
[0547] [0547] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.73 (8H, m), 6.21 (1H, q, J=6.2 Hz), 6.09 (1H, bs), 3.73 (2H, s), 2.43 (2H, q, J=7.3 Hz), 2.24 (3H, s), 1.30-1.70 (3H, m), 1.24 (3H, t, J=7.3 Hz)
[0548] Mass spectrometry (ESI-MS): 431 (M + +1)
[0549] Compound 109
[0550] 1-(2-Chlorophenyl)ethyl N-(3-methyl-5-{4-[(pentylamino)methyl]phenyl}-4-isoxazolyl)carbamate
[0551] [0551] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.75 (8H, m), 6.46 (1H, bs), 6.21 (1H, q, J=6.4 Hz), 3.81 (2H, s), 2.62 (2H, t, J=7.3 Hz), 2.23 (3H, s), 1.25-1.62 (9H, m), 0.89 (3H, t, J=6.9 Hz)
[0552] Mass spectrometry (ESI-MS): 456 (M + +1)
[0553] Compound 110
[0554] 1-(2-Chlorophenyl)ethyl N-{3-methyl-5-[4-({[2-(3-pyridyl)ethyl]amino}methyl)-phenyl]-4-isoxazolyl}carbamate
[0555] [0555] 1 H-NMR (CDCl 3 , 400 MHz): δ8.42-8.47 (2H, m), 7.70 (2H, bs), 7.00-7.55 (8H, m), 6.50 (1H, bs), 6.19-6.25 (1H, m), 3.83 (2H, s), 2.79-2.92 (4H, m), 2.24 (3H, s), 1.30-1.75 (3H, m)
[0556] Mass spectrometry (ESI-MS): 491, 493 (M + +1)
[0557] Compound 111
[0558] 1-(2-Chlorophenyl)ethyl N-{3-methyl-5-[4-({[2-(4-pyridyl)ethyl]amino}methyl)phenyl]-4-isoxazolyl}carbamate
[0559] [0559] 1 H-NMR (CDCl 3 , 400 MHz): δ8.47-8.49 (2H, m), 7.70 (2H, bs), 7.00-7.55 (8H, m), 6.46 (1H, bs), 6.21 (1H, q, J=6.4 Hz), 3.82 (2H, s), 2.78-2.95 (4H, m), 2.24 (3H, s), 1.30-1.75 (3H, m)
[0560] Mass spectrometry (ESI-MS): 491, 493 (M + +1)
[0561] Compound 112
[0562] 1-(2-Chlorophenyl)ethyl N-[5-(4-{[(2-fluoroethyl)amino]methyl}phenyl)-3-methyl-4-isoxazolyl]carbamate
[0563] [0563] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (2H, bs), 7.00-7.50 (6H, m), 6.22 (1H, q, J=6.4 Hz), 6.10 (1H, bs), 4.63 (1H, t, J=4.8 Hz), 4.51 (1H, t, J=4.7 Hz), 3.88 (1H, s), 2.96 (1H, t, J=4.8 Hz), 2.89 (1H, t, J=4.8 Hz), 2.25 (3H, s), 1.30-1.75 (3H, m)
[0564] Mass spectrometry (ESI-MS): 432, 434 (M + +1)
[0565] Compound 113
[0566] Ethyl 3-({4-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]-benzyl}amino)propanoate
[0567] [0567] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.75 (8H, m), 6.21 (1H, q, J=6.6 Hz), 6.00 (1H, bs), 4.16 (2H, q, J=7.2 Hz), 3.85 (2H, s), 2.89 (2H, t, J=6.4 Hz), 2.54 (2H, t, J=6.4 Hz), 2.25 (3H, s), 1.63 (3H, bs), 1.26 (3H, t, J=7.2 Hz)
[0568] Mass spectrometry (ESI-MS): 486, 488 (M + +1)
[0569] Compound 114
[0570] 1-(2-Chlorophenyl)ethyl N-{3-methyl-5-[4-({[(5-methyl-2-pyrazyl)methyl]amino}-methyl)phenyl]-4-isoxazoly}carbamate
[0571] [0571] 1 H-NMR (CDCl 3 , 400 MHz): δ8.47 (1H, s), 8.41 (1H, s), 7.20-7.72 (8H, m), 6.15-6.25 (1H, m), 6.00 (1H, bs), 3.94 (2H, s), 3.89 (2H, s), 2.56 (3H, s), 2.25 (3H, s), 1.00-1.75 (3H, m)
[0572] Mass spectrometry (ESI-MS): 492, 494 (M + +1)
[0573] Compound 115
[0574] Methyl 3-({4-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]-benzyl}sulfanyl)propanoate
[0575] [0575] 1 H-NMR (CDCl 3 , 400 MHz): δ7.71 (2H, bs), 7.25-7.55 (6H, m), 6.21 (1H, q, J=6.6 Hz), 6.15 (1H, bs), 3.75 (2H, s), 3.68 (3H, s), 2.66-2.71 (2H, m), 2.54-2.60 (2H, m), 2.24 (3H, s), 1.25-1.70 (3H, m)
[0576] Mass spectrometry (ESI-MS): 489 (M + +1)
[0577] Compound 116
[0578] 1-(2-Chlorophenyl)ethyl N-(5-{4-[(ethylamino)methyl]phenyl}-3-methyl-4-isoxazolyl)-carbamate
[0579] [0579] 1 H-NMR (CDCl 3 , 400 MHz): δ7.70 (2H, bs), 7.20-7.50 (6H, m), 6.32 (1H, bs), 6.21 (1H, q, J=6.6 Hz), 3.84 (3H, s), 2.75 (2H, q, J=7.0 Hz), 2.23 (3H, s), 1.35-1.70 (3H, m), 1.21 (3H, q, J=7.1 Hz)
[0580] Mass spectrometry (ESI-MS): 414, 416 (M + +1)
[0581] Compound 117
[0582] 1-(2-Chlorophenyl)ethyl N-(3-methyl-5-{4-[(propylsulfanyl)methyl]phenyl}-4-isoxazolyl)-carbamate
[0583] [0583] 1 H-NMR (CDCl 3 , 400 MHz): δ7.71 (2H, bs), 7.20-7.50 (6H, m), 6.21 (1H, q, J=6.4 Hz), 6.08 (1H, bs), 3.71 (2H, s), 2.40 (2H, t, J=7.3 Hz), 2.24 (3H, s), 1.30-1.65 (5H, m), 0.96 (3H, t, J=7.5 Hz)
[0584] Mass spectrometry (ESI-MS): 445 (M + +1)
[0585] Compound 118
[0586] Methyl 2-({4-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl}-amino)-3-methyl-5-isoxazolyl]-benzyl}-sulfanyl)acetate
[0587] [0587] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (2H, bs), 7.25-7.55 (6H, m), 6.21 (1H, q, J=6.5 Hz), 6.11 (1H, bs), 3.84 (3H, s), 3.72 (3H, s), 3.07 (2H, s), 2.24 (3H, s), 1.35-1.70 (3H, m)
[0588] Mass spectrometry (ESI-MS): 475 (M + +1)
[0589] Compound 119
[0590] Ethyl 2-({4-[{4-(i [-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)acetate
[0591] [0591] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (2H, bs), 7.20-7.55 (6H, m), 6.21 (1H, q, J=6.1 Hz), 6.15 (1H, bs), 4.18 (2H, q, J=7.1 Hz), 3.85 (2H, s), 3.05 (2H, s), 2.24 (3H, s), 1.35-1.70 (3H, m), 1.29 (3H, t, J=7.1 Hz)
[0592] Mass spectrometry (ESI-MS): 489 (M + +1)
[0593] Compound 120
[0594] 1-(2-Chlorophenyl)ethyl N-[5-(4-{[(2-hydroxyethyl)sulfanyl]methyl}phenyl)-3-methyl-4-isoxazolyl]carbamate
[0595] [0595] 1 H-NMR (CDCl 3 , 400 MHz): δ7.71 (2H, bs), 7.20-7.60 (6H, m), 6.21 (1H, q, J=6.5 Hz), 6.10 (1H, bs), 3.74 (2H, s), 3.69 (2H, t, J=6.0 Hz), 2.63 (2H, t, J=6.0 Hz), 2.24 (3H, s), 2.11 (1H, bs), 1.35-1.70 (3H, m)
[0596] Mass spectrometry (ESI-MS): 447 (M + +1)
[0597] Compound 121
[0598] 2-({4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)acetic acid
[0599] [0599] 1 H-NMR (CDCl 3 , 400 MHz): δ6.90-7.70 (9H, m), 6.14 (1H, q, J=6.4 Hz), 3.64 (2H, bs), 3.09 (2H, bs), 2.16 (3H, s), 1.30-1.60 (3H, m)
[0600] Mass spectrometry (ESI-MS): 483 (M + +23)
[0601] Compound 122
[0602] 1-(2-Chlorophenyl)ethyl N-{5-[4-({[(2R)-2-amino-3-ethyl-3-butenyl]sulfanyl}methyl)-phenyl]-3-methyl-4-isoxazolyl}carbamate
[0603] [0603] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (211, bs), 7.00-7.55 (6H, m), 6.21 (1H, q, J=6.6 Hz), 4.15-4.25 (2H, m), 3.76 (2H, s), 3.57-3.62 (1H, m), 2.79-2.85 (1H, m), 2.62-2.70 (1H, m), 2.24 (3H, s), 1.35-1.80 (3H, m), 1.26 (3H, t, J=7.1 Hz)
[0604] Mass spectrometry (ESI-MS): 518 (M + +1)
[0605] Compound 123
[0606] 1-(2-Chlorophenyl)ethyl N-(5-{4-[(allylsulfanyl)methyl]phenyl}-3-methyl-4-isoxazolyl)-carbamate
[0607] [0607] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (8H, m), 6.21 (1H, q, J=6.4 Hz), 6.09 (H, bs), 5.74-5.88 (1H, m), 5.05-5.18 (2H, s), 3.67 (2H, s), 3.02 (2H, d, J=7.1 Hz), 2.24 (3H, s), 1.30-1.70 (3H, m)
[0608] Mass spectrometry (ESI-MS): 465 (M + +23), 443 (M + +1)
[0609] Compound 124
[0610] 1-(2-Chloropbenyl)ethyl N-(3-methyl-5-4-[(phenethylsulfanyl)methyl]phenyl)-4-isoxazolyl)-carbamate
[0611] [0611] 1 H-NMR (CDCl 3 , 400 MHz): δ7.10-7.80 (13H, m), 6.21 (1H, q, J=6.4 Hz), 3.70 (2H, s), 2.82-2.88 (2H, m), 2.63-2.69 (2H, m), 2.23 (3H, s), 1.25-1.70 (3H, m)
[0612] Mass spectrometry (ESI-MS): 529 (M + +23)
[0613] Compound 125
[0614] 1-(2-Chlorophenyl)ethyl N-(5-{4-[(butylsulfanyl)methyl]phenyl)-3-methyl-4-isoxazolyl)-carbamate
[0615] Mass spectrometry (ESI-MS): 481, 483 (M + +23)
[0616] Compound 126
[0617] 3-({4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)propanoic acid
[0618] [0618] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.75 (8H, m), 6.38 (1H, bs), 6.19 (1H, q, J=6.1 Hz), 3.71 (2H, s), 2.50-2.70 (4H, m), 2.22 (3H, s), 1.30-1.70 (3H, m)
[0619] Mass spectrometry (ESI-MS): 497 (M + +23)
[0620] Compound 127
[0621] N-[2-({4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)propanoyl]carbamic acid
[0622] [0622] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.75 (8H, m), 6.17 (1H, q, J=6.4 Hz), 3.25-3.80 (3H, m), 2.96-3.20 (2H, m), 2.18 (3H, s), 1.38 (3H, s), 1.38 (3H, d, J=6.4 Hz), 1.23 (3H,t,J=7.2 Hz)
[0623] Mass spectrometry (ESI-MS): 554 (M + +23)
[0624] Compound 128
[0625] 1-(2-Chlorophenyl)ethyl N-{5-[3-(methoxymethyl)phenyl]-3-methyl-4-isoxazolyl}carbamate
[0626] [0626] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.75 (8H, m), 6.17-6.25 (1H, m), 4.46 (2H, s), 3.38 (3H, s), 2.24 (3H, s), 1.40-1.70 (3H, m)
[0627] Mass spectrometry (ESI-MS): 423 (M + +23)
[0628] Compound 129
[0629] 1-(2-Chlorophenyl)ethyl N-{5-[3-(ethoxymethyl)phenyl]-3-methyl-4-isoxazolyl}carbamate
[0630] [0630] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.80 (8H, m), 6.20 (1H, q, J=6.6 Hz), 4.50 (2H, s), 3.53 (2H, q, J=7.1 Hz), 2.24 (3H, s), 1.47-1.55 (3H, m), 1.23 (3H, t, J=7.0 Hz)
[0631] Mass spectrometry (ESI-MS): 437 (M + +23)
[0632] Compound 130
[0633] Methyl 2-({3-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]-benzyl}sulfanyl)acetate
[0634] [0634] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.75 (8H, m), 6.24 (1H, bs), 6.15 (1H, q, J=6.5 Hz), 3.76 (2H, s), 3.60 (3H, s), 2.98 (2H, s), 2.20 (3H, s), 1.45-1.60 (3H, m)
[0635] Mass spectrometry (ESI-MS): 497 (M + +23)
[0636] Compound 131
[0637] 1-(2-Chlorophenyl)ethyl N-[5-(3-{[(2-hydroxyethyl)sulfanyl]methyl}phenyl)-3-methyl-4-isoxazolyl]carbamate
[0638] [0638] 1 H-NMR (CDCl 3 , 400 MHz): δ6.90-7.75 (8H, m), 6.16 (1H, q, J=6.4 Hz), 3.66 (2H, s), 3.54-3.62 (2H, m), 2.52 (2H, bs), 2.19 (3H, s), 1.35-1.70 (3H, m)
[0639] Mass spectrometry (ESI-MS): 469 (M + +23)
[0640] Compound 132
[0641] 1-(2-Chlorophenyl)ethyl N-(5-{3-[(ethylsulfanyl)methyl]phenyl}-3-methyl-4-isoxazolyl)carbamate
[0642] [0642] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (8H, m), 6.21 (1H, q, J=6.1 Hz), 6.00 (1H, bs), 3.70 (2H, s), 2.39 (2H, q, J=7.3 Hz), 2.23 (3H, s), 1.30-1.70 (3H, m), 1.19 (3H, t, J=7.3 Hz)
[0643] Mass spectrometry (ESI-MS): 454 (M + +23)
[0644] Compound 133
[0645] Methyl 2-({4-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl amino}-3-methyl-5-isoxazolyl]-benzyl}-sulfonyl)acetate
[0646] [0646] 1 H-NMR (CDCl 3 , 400 MHz): δ7.80 (2H, s), 7.57 (2H, d, J=8.0 Hz), 7.00-7.45 (4H, m), 6.21 (1H, q, J=6.4 Hz), 6.08 (1H, bs), 4.56 (2H, s), 3.87 (3H, s), 3.80 (2H, s), 2.26 (3H, s), 1.50-1.70 (3H, m)
[0647] Mass spectrometry (ESI-MS): 529 (M + +23)
[0648] Compound 134
[0649] Methyl 2-({4-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]-benzyl}sulfinyl)acetate
[0650] [0650] 1 H-NMR (CDCl 3 , 400 MHz): δ7.10-7.80 (8H, m), 6.15 (1H, q, J=6.5 Hz), 6.03 (1H, bs), 4.21 (1H, d, J=13.1 Hz), 4.05 (1H, d, J=13.0 Hz), 3.74 (3H, s), 3.54 (1H, d, J=13.0 Hz), 3.44 (1H, d, J=13.0 Hz), 2.19 (3H, s), 1.53 (3H, bs)
[0651] Mass spectrometry (ESI-MS): 513 (M + +23)
[0652] Compound 135
[0653] 1-(2-Chlorophenyl)ethyl N-[5-(4-{[2,3-dihydroxypropyl)sulfanyl]methyl}phenyl)-3-methyl-4-isoxazolyl]carbamate
[0654] [0654] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (2H, bs), 7.20-7.60 (6H, m), 6.21 (1H, q, J=6.5 Hz), 6.11 (1H, bs), 3.76 (3H, s), 3.45-3.75 (2H, m), 2.50-2.70 (3H, m), 2.24 (3H, s), 2.02 (1H, bs), 1.60 (3H, bs)
[0655] Mass spectrometry (ESI-MS): 499 (M + +23)
[0656] Compound 136
[0657] 1-(2-Chlorophenyl)ethyl N-(3-methyl-5-{4-[(1H-1,2,4-triazol-3-ylsulfanyl)methyl]-phenyl}-4-isoxazolyl)carbamate
[0658] [0658] 1 H-NMR (CDCl 3 , 400 MHz): δ8.09 (1H, s), 7.20-7.75 (8H, m), 6.21 (1H, q, J=6.6 Hz), 6.11 (1H, bs), 4.36 (2H, s), 2.24 (3H, s), 1.30-1.75 (3H, m)
[0659] Mass spectrometry (ESI-MS): 492 (M + +23)
[0660] Compound 137
[0661] 1-(2-Chlorophenyl)ethyl N-[3-methyl-5-(4-{[(1-methyl-1H-1,2,3,4-tetrazol-5-yl)-sulfanyl]methyl}phenyl)-4-isoxazolyl]carbamate
[0662] [0662] 1 H-NMR (CDCl 3 , 400 MHz): δ7.72 (2H, bs), 7.25-7.55 (6H, m), 6.21 (1H, q, J=6.5 Hz), 5.99 (1H, bs), 4.56 (2H, s), 3.94 (3H, s), 2.25 (3H, s), 1.30-1.70 (3H, m)
[0663] Mass spectrometry (ESI-MS): 507 (M + +23)
[0664] Compound 138
[0665] 1-(2-Chlorophenyl)ethyl N-{3-methyl-5-[4-([2-(methylamino)-2-oxoethyl]sulfanyl}-methyl)phenyl]-4-isoxazolyl}carbamate
[0666] [0666] 1 H-NMR (CDCl 3 , 400 MHz): δ7.73 (2H, bs), 7.20-7.55 (6H, m), 6.54 (1H, bs), 6.21 (1H, q, J=6.5 Hz), 6.12 (1H, bs), 3.74 (2H, s), 3.12 (2H, s), 2.75 (3H, d, J=4.9 Hz), 2.25 (3H, s), 1.30-1.70 (3H, m)
[0667] Mass spectrometry (ESI-MS): 474 (M + +1), 496 (M + +23)
[0668] Compound 139
[0669] 1-(2-Chlorophenyl)ethyl N-(5-{4-[({2-[(2-furylmethyl)amino]-2-oxoethyl}sulfanyl)-methyl]phenyl)-3-methyl-4-isoxazolyl)carbamate
[0670] [0670] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.75 (9H, m), 6.83 (1H, bs), 6.10-6.26 (4H, m), 4.32 (2H, d, J=5.4 Hz), 3.64 (2H, s), 3.05 (2H, s), 2.17 (3H, s), 1.30-1.65 (3H, m)
[0671] Mass spectrometry (ESI-MS): 562 (M + +23)
[0672] Compound 140
[0673] Ethyl 2-({3-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)acetate
[0674] [0674] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (8H, m), 6.32 (1H, bs), 6.20 (1H, q, J=6.4 Hz), 4.05-4.20 (2H, m), 3.81 (2H, s), 3.02 (2H, s), 2.24 (3H, s), 1.30-1.70 (3H, m), 1.24 (3H, t, J=7.2 Hz)
[0675] Mass spectrometry (ESI-MS): 487 (M + −1), 511 (M + +23)
[0676] Compound 141
[0677] 1-(2-Chlorophenyl)ethyl N-(5-{3-[(allylsulfanyl)methyl]phenyl}-3-methyl-4-isoxazolyl)-carbamate
[0678] [0678] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.75 (8H, m), 6.16 (1H, q, J=6.6 Hz), 5.95 (1H, bs), 5.65-5.77 (1H, m), 4.97-5.10 (2H, m), 3.60 (2H, s), 2.95 (2H, dt, J=7.1 Hz, J=1.1 Hz), 2.19 (3H, s), 1.45-1.60 (3H, m)
[0679] Mass spectrometry (ESI-MS): 441 (M + −1), 465 (M + +23)
[0680] Compound 142
[0681] 1-(2-Chlorophenyl)ethyl N-(3-methyl-5-{3-[(phenethylsulfanyl)methyl]phenyl}-4-isoxazolyl)-carbamate
[0682] [0682] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.75 (13H, m), 6.15 (1H, q, J=6.4 Hz), 5.90 (1H, bs), 3.64 (2H, s), 2.76 (2H, t, J=7.8 Hz), 2.59 (2H, t, J=7.8 Hz), 2.19 (3H, s), 1.45-1.52 (3H, m)
[0683] Mass spectrometry (ESI-MS): 505 (M + −1), 529 (M + +23)
[0684] Compound 143
[0685] 1-(2-Chlorophenyl)ethyl N-(3-methyl-5-{3-[(1H-1,2,4-triazol-3-ylsulfanyl)methyl]phenyl}-4-isoxazolyl)carbamate
[0686] [0686] 1 H-NMR (CDCl 3 , 400 MHz): δ6.00-8.00 (11H, m), 4.23 (2H, s), 2.23 (3H, s), 1.00-1.65 (3H, m)
[0687] Mass spectrometry (ESI-MS): 468 (M + −1), 492 (M + +23)
[0688] Compound 144
[0689] 4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl ethanethioate
[0690] [0690] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.75 (8H, m), 6.05-6.15 (2H, m), 4.04 (2H, s), 2.28 (3H, s), 2.15 (3H, s), 1.25-1.65 (3H, m)
[0691] Mass spectrometry (ESI-MS): 445 (M + +1)
[0692] Compound 145
[0693] 1-(2-Chlorophenyl)ethyl N-{5-[4-({[2-(acetylamino)ethyl]sulfanyl}methyl)phenyl]-3-methyl-4-isoxazolyl} carbamate
[0694] [0694] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.75 (8H, m), 6.54 (1H, bs), 6.13 (1H, q, J=6.3 Hz), 5.84 (1H, bs), 3.64 (2H, s), 3.24 (2H, d, J=5.8 Hz), 2.46 (2H, t, J=5.8 Hz), 2.16 (3H, s), 1.86 (3H, ss), 1.25-1.70 (3H, m)
[0695] Mass spectrometry (ESI-MS): 488 (M + +1), 510 (M + +23)
[0696] Compound 146
[0697] Methyl 3-({4-[4-([1-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-ethyl-5-isoxazolyl]-benzyl}sulfanyl)propanoate
[0698] [0698] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.80 (8H, m), 6.21 (1H, q, J=6.4 Hz), 5.97 (1H, bs), 3.75 (2H, s), 3.69 (3H, s), 2.54-2.73 (6H, m), 1.50-1.70 (3H, m), 1.30 (3H, t, J=7.6 Hz)
[0699] Mass spectrometry (ESI-MS): 503 (M + +1), 525 (M + +23)
[0700] Compound 147
[0701] 3-({4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-ethyl-5-isoxazolyl]benzyl}-sulfanyl)propanoic acid
[0702] [0702] 1 H-NMR (CDCl 3 , 400 MHz): δ6.70-7.75 (8H, m), 6.00-6.18 (2H, m), 3.67 (2H, s), 2.49-2.64 (6H, m), 1.16-1.60 (6H, m)
[0703] Mass spectrometry (ESI-MS): 489 (M + +1), 511 (M + +23)
[0704] Compound 148
[0705] 2-({4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)propanoic acid
[0706] [0706] 1 H-NMR (CDCl 3 , 400 MHz): δ7.64 (2H, bs), 6.80-7.50 (6H, m), 6.14 (1H, q, J=6.5 Hz), 3.86 (1H, d, J=13.7 Hz), 3.74 (1H, d, J=13.7 Hz), 3.21 (1H, q, J=7.3 Hz), 2.17 (3H, s), 1.30-1.60 (3H, m), 1.33 (3H, d, J=7.3 Hz)
[0707] Mass spectrometry (ESI-MS): 475 (M + +1), 497 (M + +23)
[0708] Compound 149
[0709] 1-(2-Chlorophenyl)ethyl N-(3-methyl-5-{4-[({2-[(1H-2-pyrrolylcarbonyl)amino]ethyl}-sulfanyl)methyl]phenyl}-4-isoxazolyl)carbamate
[0710] [0710] 1 H-NMR (CDCl 3 , 400 MHz): δ7.68 (2H, d, J=8.3 Hz), 7.00-7.55 (7H, m), 6.89 (1H, bs), 6.52 (1H, s), 5.95-6.40 (3H, m), 3.76 (2H, s), 3.45 (1H, bs), 3.11 (1H, bs), 2.63 (2H, s), 2.25 (3H, s), 1.59 (3H, s)
[0711] Mass spectrometry (ESI-MS): 539 (M + +1)
[0712] Compound 150
[0713] 1-(2-Chlorophenyl)ethyl N-[5-(4-{[(2-chloroethyl)sulfanyl]methyl}phenyl)-3-methyl-4-isoxazolyl] carbamate
[0714] [0714] 1 H-NMR (CDCl 3 , 400 MHz): δ7.71 (2H, bs), 7.00-7.60 (6H, m), 6.20 (1H, q, J=6.5 Hz), 5.96 (1H, bs), 3.72 (2H, t, J=7.2 Hz), 3.09 (2H, t, J=7.2 Hz), 2.23 (3H, s), 1.30-1.70 (3H, m)
[0715] Mass spectrometry (ESI-MS): 417, 419 (M+1), 441 (M+23)
[0716] Compound 151
[0717] 2-({4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)-1-ethanesulfonic acid
[0718] [0718] 1 H-NMR (CDCl 3 , 400 MHz): δ9.44 (1H, s), 7.40-8.00 (8H, m), 6.05 (1H, q, J=6.4 Hz), 4.57 (1H, s), 3.85 (1H, s), 3.25-3.30 (2H, m), 2.70 (3H, s), 2.15-2.25 (2H, m), 1.30-1.45 (3H, m)
[0719] Mass spectrometry (ESI-MS): 509, 511 (M + −1)
[0720] Compound 152
[0721] 3-({4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)-1-propanesulfonic acid
[0722] [0722] 1 H-NMR (CDCl 3 , 400 MHz): δ9.70 (1H, s), 7.30-7.90 (8H, m), 5.90-6.05 (1H, m), 4.52 (1H, s), 3.76 (1H, s), 3.14-3.23 (2H, m), 2.48-2.53 (3H, m), 2.09-2.17 (2H, m), 1.75-1.90 (2H, m), 1.32 (3H, t, J=7.2 Hz)
[0723] Mass spectrometry (ESI-MS): 523 (M + −1)
[0724] Compound 153
[0725] Methyl 2-({4-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-ethyl-5-isoxazolyl]benzyl}-sulfanyl)acetate
[0726] [0726] 1 H-NMR (CDCl 3 , 400 MHz): δ7.25-7.80 (8H, m), 6.21 (1H, q, J=6.6 Hz), 5.97 (1H, bs), 3.85 (2H, s), 3.73 (3H, s), 3.07 (2H, s), 2.66 (2H, q, J=7.6 Hz), 1.50-1.70 (3H, m), 1.30 (3H, t, J=7.6 Hz)
[0727] Mass spectrometry (ESI-MS): 511 (M + +23)
[0728] Compound 154
[0729] 2-({4-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-ethyl-5-isoxazolyl]benzyl}-sulfanyl)acetic acid
[0730] [0730] 1 H-NMR (CDCl 3 , 400 MHz): δ6.75-7.60 (9H, m), 6.03 (1H, q, J=6.4 Hz), 3.40-3.65 (2H, m), 3.02 (2H, bs), 2.40-2.55 (2H, m), 1.10-1.46 (6H, m)
[0731] Mass spectrometry (ESI-MS): 497 (M + +23)
[0732] Compound 155
[0733] 1-(2-Fluorophenyl)ethyl N-{5-[4-(chloromethyl)phenyl]-3-methyl-4-isoxazolyl}carbamate
[0734] [0734] 1 H-NMR (CDCl 3 , 400 MHz): δ7.74 (2H, bs), 6.90-7.50 (6H, m), 6.13 (1H, q, J=6.6 Hz), 6.02 (1H, bs), 4.60 (2H, s), 2.24 (3H, s), 1.50-1.70 (3H, m)
[0735] Mass spectrometry (ESI-MS): 387 (M + −1)
[0736] Compound 156
[0737] Methyl 3-({4-[4-({[1-(2-fluorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]-benzyl}-sulfanyl)propanoate
[0738] [0738] 1 H-NMR (CDCl 3 , 400 MHz): δ7.64 (2H, bs), 6.80-7.40 (6H, m), 6.06 (1H, q, J=6.6 Hz), 5.99 (1H, bs), 3.68 (2H, s), 3.61 (3H, s), 2.59-2.60 (2H, m), 2.47-2.52 (2H, m), 2.16 (3H, s), 1.48-1.65 (3H, m)
[0739] Mass spectrometry (ESI-MS): 495 (M + +23)
[0740] Compound 157
[0741] 3-({4-[4-({[1-(2-Fluorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)propanoic acid
[0742] [0742] 1 H-NMR (CDCl 3 , 400 MHz): δ7.62 (2H, bs), 6.70-7.50 (6H, m), 6.12 (1H, bs), 6.05 (1H, q, J=6.4 Hz), 3.67 (2H, s), 2.48-2.65 (4H, m), 2.16 (3H, s), 2.10 (2H, s), 1.16-1.64 (3H, m)
[0743] Mass spectrometry (ESI-MS): 481 (M + +23)
[0744] Compound 158
[0745] 2-({3-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)-1-ethanesulfonic acid
[0746] [0746] 1 H-NMR (CDCl 3 , 400 MHz): δ6.90-8.20 (8H, m), 6.00-6.20 (2H, m), 4.43 (1H, bs), 3.57 (2H, s), 2.55-3.20 (4H, m), 2.09 (3H, s), 1.00-1.75 (3H, m)
[0747] Mass spectrometry (ESI-MS): 509, 511 (M + +1)
[0748] Compound 159
[0749] 3-({3-[4-({[1-(2-Chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]benzyl}-sulfanyl)propanoic acid
[0750] [0750] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.90 (8H, m), 6.28 (1H, bs), 6.18 (1H, q, J=6.4 Hz), 3.67 (2H, s), 2.45-2.65 (4H, m), 2.20 (3H, s), 1.40-1.60 (3H, m)
[0751] Mass spectrometry (ESI-MS): 473 (M−1) 497 (M + +23)
[0752] Compound 160
[0753] 1-(2-Fluorophenyl)ethyl N-{5-[4-(chloromethyl)phenyl]-3-ethyl-4-isoxazolyl}carbamate
[0754] [0754] 1 H-NMR (CDCl 3 , 400 MHz): δ7.71 (2H, bs), 6.90-7.50 (6H, m), 6.10 (1H, q, J=6.6 Hz), 5.95 (1H, bs), 4.58 (2H, s), 2.63 (2H, q, J=7.6 Hz), 1.50-1.70 (3H, m), 1.27 (3H, t, J=7.6 Hz)
[0755] Mass spectrometry (ESI-MS): 401 (M + −1)
[0756] Compound 161
[0757] 2,2,2-Trifluoro-1-phenylethyl N-{5-[4-(chloromethyl)phenyl]-3-methyl-4-isoxazolyl}-carbamate
[0758] [0758] 1 H-NMR (CDCl 3 , 400 MHz): 7.69 (2H, d, J=7.3 Hz), 7.20-7.60 (7H, m), 6.32 (1H, bs), 6.10-6.20 (1H, m), 4.59 (2H, s), 2.24 (3H, s)
[0759] Mass spectrometry (ESI-MS): 425 (M + +1), 445, 447 (M + +23)
[0760] Compound 162
[0761] Methyl 3-{[4-(3-methyl-4-{[(2,2,2-trifluoro-1-phenylethoxy)carbonyl]amino}-5-isoxazolyl)-benzyl]-sulfanyl}propanoate
[0762] [0762] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.75 (9H, m), 6.25 (1H, bs), 6.10-6.20 (1H, m), 3.75 (2H, s), 3.69 (3H, s), 2.66-2.72 (2H, m), 2.53-2.59 (2H, m), 2.24 (3H, s)
[0763] Mass spectrometry (ESI-MS): 531, 532 (M + +23)
[0764] Compound 163
[0765] 3-{[4-(3-Methyl-4-{[(2,2,2-trifluoro-1-phenylethoxy)carbonyl]amino}-5-isoxazolyl)benzyl]-sulfanyl}propanoic acid
[0766] [0766] 1 H-NMR (CDCl 3 , 400 MHz): δ7.20-7.75 (9H, m), 6.54 (1H, bs), 6.10-6.20 (1H, m), 3.72 (2H, s), 2.50-2.80 (4H, m), 2.23 (3H, s)
[0767] Mass spectrometry (ESI-MS): 493 (M + −1)
[0768] Compound 164
[0769] 2,2,2-Trifluoro-1-phenylethyl N-{5-[4-(chloromethyl)phenyl]-3-ethyl-4-isoxazolyl}carbamate
[0770] [0770] 1 H-NMR (CDCl 3 , 400 MHz): δ7.00-7.75 (9H, m), 6.16-6.26 (1H, m), 6.00-6.12 (1H, m), 4.52 (2H, s), 2.57 (2H, q, J=7.5 Hz), 1.21 (3H, t, J=7.5 Hz)
[0771] Mass spectrometry (ESI-MS): 437 (M + −1)
[0772] Compound 165
[0773] Methyl 3-({4-[3-ethyl-4-({[1-(2-fluorophenyl)ethoxy]carbonyl}amino)-5-isoxazolyl]-benzyl}sulfanyl)propanoate
[0774] [0774] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.75 (8H, m), 6.06 (1H, q, J=6.6 Hz), 5.90 (1H, bs), 3.68 (2H, s), 3.62 (3H, s), 2.54-2.65 (4H, m), 2.47-2.53 (2H, m), 1.30-1.65 (3H, in), 1.21 (3H, t, J=7.6 Hz)
[0775] Mass spectrometry (ESI-MS): 485 (M + −1), 509 (M + +23)
[0776] Compound 166
[0777] Methyl 3-{[4-(3-ethyl-4-{[(2,2,2-trifluoro-1-phenylethoxy)carbonyl]amino}-5-isoxazolyl)-benzyl]sulfanyl}propanoate
[0778] [0778] 1 H-NMR (CDCl 3 , 400 MHz): δ7.10-7.70 (9H, m), 6.20 (1H, bs), 6.00-6.13 (1H, m), 3.67 (2H, s), 3.61 (3H, s), 2.46-2.64 (6H, m), 1.21 (3H, t, J=7.4 Hz)
[0779] Mass spectrometry (ESI-MS): 521 (M + −1), 545 (M + +23)
[0780] Compound 167
[0781] 3-({4-[3-Ethyl-4-({[1-(2-fluorophenyl)ethoxy]carbonyl}amino)-5-isoxazolyl]benzyl}-sulfanyl)propanoic acid
[0782] [0782] 1 H-NMR (CDCl 3 , 400 MHz): δ6.80-7.70 (8H, m), 6.05 (1H, q, J=6.6 Hz), 5.94 (1H, bs), 3.69 (2H, s), 2.49-2.65 (6H, m), 1.25-1.70 (3H, in), 1.21 (3H, t, J=7.6 Hz)
[0783] Mass spectrometry (ESI-MS): 471 (M + −1), 495 (M + +23)
[0784] Compound 168
[0785] Ethyl 2-({4-[4-({[1-(2-chlorophenyl)ethoxy]carbonyl}amino)-3-methyl-5-isoxazolyl]-benzyl}oxy)acetate
[0786] [0786] 1 H-NMR (CDCl 3 , 400 MHz): δ7.75 (2H, bs), 7.25-7.55 (6H, m), 6.22 (1H, q, J=6.5 Hz), 6.03 (1H, bs), 4.67 (2H, s), 4.24 (2H, q, J=7.2 Hz), 4.12 (2H, s), 2.25 (3H, s), 1.40-1.70 (3H, m), 1.30 (3H, t, J=7.2 Hz)
[0787] Mass spectrometry (ESI-MS): 495 (M + +23)
[0788] Compound 169
[0789] Ethyl 2-{[4-(3-methyl-4-{[(2,2,2-trifluoro-1-phenylethoxy)carbonyl]amino}-5-isoxazolyl)-benzyl]oxy}acetate
[0790] [0790] 1 H-NMR (CDCl 3 , 400 MHz): δ7.65-7.75 (2H, m), 7.20-7.60 (7H, m), 6.44 (1H, bs), 6.10-6.20 (1H, m), 4.66 (2H, s), 4.25 (2H, q, J=7.2 Hz), 4.13 (2H, s), 2.23 (3H, s), 1.30 (3H, t, J=7.2 Hz)
[0791] Mass spectrometry (ESI-MS): 491 (M + −1)
Example 170
[0792] Establishment of HepG2 Cell Line Expressing Human EDG-2
[0793] An about 360 bp DNA fragment, which corresponds to that reported by An et al. (Biochem. Biophys. Res. Commun. 231: 619 (1997)), was obtained by PCR (polymerase chain reaction) from the human brain cDNA library (Clontech Laboratories Inc., USA). The total nucleotide sequence was determined using a DNA sequenser, and it was confirmed that the sequence corresponds completely to that reported by An et al. (Biochem. Biophys. Res. Commun.231: 619 (1997)). cDNA of the cloned human EDG-2 was introduced into pEFneo, which is an animal expression vector (Proc. Natl. Acad. Sci. USA 91: 158 (1994)) to obtain a human EDG-2 expression plasmid. The human EDG-2 expression plasmid was introduced into HepG2 cells by electroporation. After the introduction, culturing was continued while exchanging selective media every 3 to 4 days, thereby obtaining an expressed colony. Regarding these cells, Ca-influx and cell-proliferation by LPA, level of [ 3 H] LPA binding and the like were inspected to select a cell line which highly expresses human EDG-2 (human EDG-2/HepG2). The obtained cell line was used to assay the activity in the following Examples 104 and 105.
Example 171
[0794] Assay of Inhibitory Activity on Cell Activation (Function for Elevating Intracellular Ca 2+ Level)
[0795] Human EDG-2/HepG2 cells were washed and then suspended in 0.1% BSA (bovine serum albumin)-containing HEPES buffer. A fluorescent indicator, fura-2/AM (Wako Pure Chemical Industries, Ltd.), was added, and the mixture was shaken at room temperature for 45 minutes so that the indicator is included in the cell. Cells were washed again and then suspended in 0.1% BSA-containing HEPES buffer, and intracellular Ca 2+ level was assayed using FDSS2000 (Hamamatsu Photonics). The compounds obtained in Examples 1 to 102 were used as test compounds for Compound Nos.1 to 102. Each test compound was added to the cell suspension followed by the addition of LPA, thereby examining the inhibitory activity of the test compound on the function of LPA for elevating the intracellular Ca level. The elevation of intracellular Ca 2+ level by LPA without the addition of test compounds was set as 100% and resting Ca 2+ level before the addition of LPA was set as 0%, thereby determining the concentration of 50% inhibition for the elevation of intracellular Ca 2+ level (IC 50 value). The lower the IC 50 value, the higher the antagonistic activity on the LPA receptor. The results are shown in Table 1.
TABLE 1 Compound No. IC 50 (μM) Compound 1 100 Compound 2 30 to 100 Compound 3 3 Compound 4 3 Compound 5 10 to 30 Compound 6 10 Compound 7 30 Compound 8 3 to 10 Compound 9 10 to 30 Compound 10 100 to Compound 11 10 to 30 Compound 12 30 to 100 Compound 13 30 Compound 14 30 to 100 Compound 15 30 Compound 16 3 to 10 Compound 17 3 Compound 18 3 Compound 19 3 to 10 Compound 20 3 Compound 21 3 Compound 22 3 to 10 Compound 23 10 Compound 24 100 Compound 25 30 to 100 Compound 26 100 Compound 27 30 Compound 28 10 to 30 Compound 29 10 Compound 30 3 to 10 Compound 31 10 Compound 32 3 Compound 33 3 to 10 Compound 34 10 Compound 35 3 to 10 Compound 36 3 to 10 Compound 37 30 Compound 38 10 Compound 39 10 Compound 40 10 Compound 41 3 to 10 Compound 42 10 Compound 43 3 to 10 Compound 44 3 Compound 45 3 Compound 46 3 to 10 Compound 47 1 Compound 48 3 to 10 Compound 49 10 to 30 Compound 50 10 to 30 Compound 51 10 to 30 Compound 52 30 Compound 53 30 Compound 54 10 to 30 Compound 55 3 to 10 Compound 56 3 to 10 Compound 57 3 Compound 58 10 Compound 59 3 to 10 Compound 60 1 to 3 Compound 61 3 to 10 Compound 62 3 Compound 63 30 Compound 64 10 to 30 Compound 65 10 to 30 Compound 66 10 Compound 67 3 Compound 68 3 to 10 Compound 69 3 to 10 Compound 70 1 to 3 Compound 71 3 Compound 72 10 to 30 Compound 73 1 to 3 Compound 74 1 to 3 Compound 75 3 to 10 Compound 76 1 to 3 Compound 77 1 to 3 Compound 78 30 Compound 79 3 Compound 80 1 to 3 Compound 81 30 to 100 Compound 82 10 to 30 Compound 83 10 Compound 84 3 to 10 Compound 85 3 to 10 Compound 86 1 to 3 Compound 87 3 Compound 88 3 to 10 Compound 89 10 to 30 Compound 90 10 Compound 91 10 to 30 Compound 92 10 to 30 Compound 93 3 to 10 Compound 94 30 to 100 Compound 95 30 to 100 Compound 96 30 to 100 Compound 97 30 to 100 Compound 98 30 to 100 Compound 99 30 to 100 Compound 100 30 to 100 Compound 101 30 to 100 Compound 102 30 to 100 Compound 103 10 Compound 104 10 to 30 Compound 105 10 to 30 Compound 106 3 to 10 Compound 107 3 to 10 Compound 108 3 to 10 Compound 109 10 to 30 Compound 110 10 to 30 Compound 111 10 to 30 Compound 112 10 to 30 Compound 113 10 to 30 Compound 114 10 to 30 Compound 115 1 to 3 Compound 116 30 to 100 Compound 117 3 to 10 Compound 118 1 to 3 Compound 119 3 to 10 Compound 120 3 to 10 Compound 121 3 to 10 Compound 122 3 to 10 Compound 123 3 to 10 Compound 124 10 to 30 Compound 125 10 to 30 Compound 126 3 to 10 Compound 127 3 to 10 Compound 128 3 to 10 Compound 129 3 to 10 Compound 130 3 to 10 Compound 131 3 Compound 132 3 Compound 133 10 Compound 134 3 to 10 Compound 135 3 to 10 Compound 136 3 to 10 Compound 137 3 to 10 Compound 138 3 to 10 Compound 139 10 Compound 140 3 to 10 Compound 141 3 to 10 Compound 142 3 to 10 Compound 143 3 to 10 Compound 144 1 to 3 Compound 145 3 to 10 Compound 146 3 to 10 Compound 147 3 to 10 Compound 148 10 to 30 Compound 149 10 to 30 Compound 150 3 Compound 151 3 to 10 Compound 152 3 to 10 Compound 153 3 to 10 Compound 154 3 to 10 Compound 155 3 to 10 Compound 156 10 Compound 157 3 Compound 158 3 to 10 Compound 159 3 Compound 160 3 to 10 Compound 161 3 to 10 Compound 162 3 to 10 Compound 163 3 to 10 Compound 164 3 to 10 Compound 165 3 to 10 Compound 166 10 Compound 167 3 to 10 Compound 168 3 to 10 Compound 169 3 to 10
[0796] As is apparent from Table 1 above, most of the tested compounds had IC 50 of 100 μM or below and, particularly, Compound Nos. 3, 4, 6, 8, 16, 17, 18, 19, 20, 21, 22, 23, 29, 30, 31, 32, 33, 34, 35, 36, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 55, 56, 57, 58, 59, 60, 61, 62, 66, 67, 68, 69, 70, 71, 73, 74, 75, 76, 77, 79, 80, 83, 84, 85, 86, 87, 88, 90, 93, 103, 106 to 108, 115, 117 to 123, 126 to 147, and 150 to 169 had IC 50 of 10 μM or below. This indicates that the antagonistic action on the LPA receptor is high.
Example 172
[0797] Assay of inhibitory activity on [ 3 H] Thymidine Incorporation
[0798] Human EDG-2/HepG2 cells suspended in 10% bovine serum-containing DMEM (Dulbecco's modified eagle medium) were plated on a 96-well plate and, on the next day, the medium was exchanged with serum-free DMEM. 24 hours later, the medium was exchanged with DMEM containing LPA or DMEM containing no LPA, cells were cultured for further 16 hours, and [ 3 H] thymidine was then added. After culturing for 8 hours subsequent to the addition of [ 3 H] thymidine, cells were washed with PBS (phosphate-buffered saline), and the amount of [ 3 H] thymidine incorporated into the cells were assayed by Betaplate filter counter system (Amersham Pharmacia Biotech). The difference between the amount of [ 3 H] thymidine incorporated in the LPA-added well and the amount of [ 3 H] thymidine incorporated in the well containing no LPA represents the amount of [ 3 H] thymidine incorporation accelerated by LPA. The increase of [ 3 H] thymidine incorporation without the addition of test compounda was set as 100% and the concentration of compound with 50% inhibition in the increase of [ 3 H] thyrnidine incorporation (IC 50 value) was determined. The test compounds were added immediately before the LPA addition. The results are shown in Table 2.
TABLE 2 Inhibition of Compound No. proliferation IC 50 (μM) Compound 4 1 Compound 20 1 Compound 32 1 Compound 47 0.3 Compound 62 3 Compound 67 1 Compound 71 1 Compound 103 0.3 Compound 104 3 Compound 105 1 Compound 106 1 to 3 Compound 107 0.03 to 0.1 Compound 108 0.1 to 0.3 Compound 109 1 to 3 Compound 110 0.3 to 1 Compound 111 1 to 3 Compound 112 0.3 to 1 Compound 113 0.1 to 0.3 Compound 114 0.3 to 1 Compound 115 0.01 to 0.03 Compound 116 0.3 to 1 Compound 117 0.03 to 0.1 Compound 118 0.1 to 0.3 Compound 119 0.1 to 0.3 Compound 120 0.1 to 0.3 Compound 121 0.03 to 0.1 Compound 122 0.1 to 0.3 Compound 123 0.1 to 0.3 Compound 124 0.1 to 0.3 Compound 125 0.1 to 0.3 Compound 126 0.01 to 0.03 Compound 127 0.1 to 0.3 Compound 128 0.1 to 0.3 Compound 129 0.3 to 1 Compound 130 0.3 to 1 Compound 132 0.3 to 1 Compound 133 0.1 to 0.3 Compound 134 0.1 to 0.3 Compound 135 0.1 to 0.3 Compound 136 0.1 to 0.3 Compound 137 0.1 to 0.3 Compound 138 0.1 to 0.3 Compound 139 0.03 to 0.1 Compound 140 0.3 to 1 Compound 141 0.3 to 1 Compound 142 0.3 Compound 143 0.1 to 0.3 Compound 144 0.03 to 0.1 Compound 145 0.3 to 1 Compound 146 0.03 to 0.3 Compound 147 0.03 to 0.1 Compound 148 0.1 to 0.3 Compound 149 0.03 Compound 150 0.1 to 0.3 Compound 151 0.1 Compound 152 0.3 Compound 153 0.3 Compound 154 0.1 to 0.3 Compound 156 0.3 to 1 Compound 157 0.3 to 1 Compound 158 1 Compound 159 0.3 Compound 161 1 to 3 Compound 162 0.03 to 0.1 Compound 163 0.03 to 0.1 Compound 164 0.3 to 1 Compound 165 0.1 to 0.3 Compound 166 0.1 Compound 167 0.03 to 0.1 Compound 168 1 Compound 169 1 to 3
[0799] As is apparent from Table 2 above, the compounds of the present invention significantly inhibit the incorporation of [ 3 H] thymidine into the cells. This indicates that the compounds of the present invention possess an inhibitory property against cell proliferation. The compounds shown in Table 2 are simple representative examples. Other compounds shown in Table 1 also inhibit the incorporation of [ 3 H] thymidine in the same manner as described above.
Example 173
[0800] Evaluation of the Function Against a Model of Lactic Acid Induced Peripheral Circulatory Disturbance
[0801] Peripheral arterial obstructions including clinical arteriosclerosis obliterans (ASO) are, in common, chronic diseases, which often cause ulcer or necrosis in lower limbs, and lesions are worsened by arterial thrombotic infarcts upstream of the lesions. Therefore, the target of the treatment for the above diseases is to inhibit the progress and to eliminate the ischemic symptoms. Antiplatelet drugs and anticoagulants are often used therefor. Since lysophosphatidic acids (LPA) are known to be released from activated platelets, the compounds according to the present invention can be sufficiently expected to exhibit therapeutic effects on the above diseases. ID3016511 (Compound 115), which is one of the compounds according to the present invention, is selected as an example and administered daily to a rat model of lactic acid induced peripheral circulatory disturbance used as an animal model of peripheral arterial obstruction to examine the drug's therapeutic effect.
[0802] 13-week old Wister male rats were used in test groups of 10 rats. Each rat was fixed in a face-up position under anesthesia by 40 mg/kg of intraperitoneally administered pentobarbital sodium. The left femoral region was then incised and 0.1 ml of 5% lactic acid solution was administered into the femoral artery. Adhesives were applied dropwise at the lactic acid administered site for blood stanching. Thereafter, a penicillin G solution was added dropwise to prevent infections and the incised part was sutured. Test compound ID3016511, which is a white powder and has poor solubility in water, was suspended in an aqueous solution of 0.5% carboxymethylcellulose sodium (0.5% CMC-Na) and test solutions of a maximal dosage of 60 mg/S ml/kg (body weight) and a low dosage of 20 mg/S ml/kg (body weight) were prepared. The solvent and the test solution were orally administered. Administration was carried out 2 hours before lactic acid administration and, thereafter, twice a day at an interval of at least 7 hours for 13 days repeatedly. Ticlopidine (Sigma) at the dosage of 300 mg/5 ml/kg (body weight) was used as a positive control material with the aid of an aqueous solution of 0.5% CMC-Na. The positive control material was administered 3 hours before the lactic acid administration, and it was repeatedly orally administered twice a day for 13 days in the same way as the above test compound. The progress of lesion on legs and feet was observed 3, 7, and 14 days after the lactic acid administration and the results were scored from 0 to 4 based on the following criteria:
[0803] (Scores)
[0804] 0: no lesion
[0805] 1: nigrities limited to the tiptoe
[0806] 2: nigrities reaching toe
[0807] 3: necrosis of toe
[0808] 4: exfoliation of toe
[0809] Each toe was scored and the sum of scores for each toe was determined as a lesion index. When the damage reached the sole, 5 points were added.
[0810] The results of this test are shown in Table 3. The test results are indicated by the average±the standard error. The significant difference between the control group and the test material group was assayed by the non-parametric Dunnet's test. The significant difference between the control group and the positive control material group was assayed by the non-parametric Wilcoxon's test. The lesion index of the control group was 2.5±0.5 at three days after lactic acid administration, 4.3±0.9 at seven days after the administration, and 7.7±1.5 at fourteen days after the administration. In the group of repeated administration of 20 mg/kg of ID3016511 for 14 days, the equivalent level of progress with the control group was observed in the lesion. In the group of repeated administration of 60 mg/kg of ID3016511, an inhibitory tendency in the lesion index began to be exhibited 3 days after lactic acid administration and the lesion index was significantly inhibited 14 days after lactic acid administration. A single dose of 300 mg/kg of ticlopidine, which was a positive control material, significantly inhibited the lesion index from 3 days after lactic acid administration.
[0811] As is apparent from the above results, the compound ID3016511 (Compound 115) according to the present invention inhibited the progress of lesions in the feet and legs at the dose of 60 mg/kg. Other compounds shown in Table 1, which are structurally similar with Compound 115, are considered to exhibit similar actions.
TABLE 3 Effects of ID3016511 and ticlopidine on lactic acid induced peripheral circulatory disturbance in rats Score of lesion Number of days Dosage Number of after lactic acid injection Drug (mg/kg, twice/day) animals 3 7 14 Control a) 10 2.5 ± 0.5 4.3 ± 0.9 7.7 ± 1.5 ID3016511 20 10 2.6 ± 0.8 4.3 ± 1.0 6.9 ± 1.4 60 10 1.1 ± 0.4 1.9 ± 0.5 3.2 ± 0.7* Ticlopidine b) 300 10 0.4 ± 0.2 ## 1.2 ± 0.4 # 1.6 ± 0.4 ##
Example 174
[0812] Assay of Inhibitory Activity Against the BrdU Incorporation
[0813] Human brain tumor cells (U87 MG) and ovarian carcinoma cells (SKOV3) suspended in serum-free DMEM were plated on a 96-well plate. 24 hours later, Compound 115 and LPA (3 μM) were added and the mixture was cultured for 16 hours, followed by the BrdU addition. Culture was continued for 3 hours from the addition of BrdU. Thereafter, the incorporation of BrdU into the cells was assayed based on the absorbance at 450 nm using the Cell proliferation ELISA system (RPN250, Amersham LIFE SCIENCE). The results thereof are shown in FIGS. 2A and 2B.
[0814] As is apparent from these figures, Compound 115 inhibited the proliferation of carcinoma cells in a concentration dependent manner at a concentration of 0.3 μM or higher.
INDUSTRIAL APPLICABILITY
[0815] The present invention provides a formulation comprising an azole compound having an antagonistic action on an LPA receptor and a pharmaceutically acceptable salt thereof. The formulation exhibits excellent preventive and therapeutic properties against restenosis after percutaneous transluminal coronary angioplasty (PTCA), arteriosclerosis, artery obstruction, malignant and benign proliferative diseases, various inflammatory diseases, kidney diseases, proliferation of tumor cells, carcinoma invasion/metastasis, brain or periphery nerve disorders and the like.
[0816] The present invention has been described with reference to specific examples in the above. The present invention is, however, not limited to the above examples and various changes and modification should be construed as possible as long as they are within the range of equivalence not departing from the idea and the scope of the present invention as set forth in the accompanying claims. Various literatures cited herein (including patents and patent applications) are incorporated by reference in their entirety. | The present invention relates to novel isoxazole and thiazole compounds having an excellent lysophosphatidic acid (LPA) receptor antagonistic activity represented by general formula [1] or salts thereof:
wherein R1 and R2 represents an optionally substituted alkyl group or the like; R3 represents a hydrogen atom or the like; R4 represent a group selected from the group consisting of (I) optionally substituted phenyl, aryl, or heterocycle, (II) substituted or nonsubstituted alkyl, and (III) substituted or nonsubstituted alkenyl, alternatively, R3 and R4 may form a ring structure together with a carbon atom to which they bind; and X represents an oxygen atom or a sulfur atom, provided that, when R3 is a hydrogen atom, R4 represents a group other than methyl, and the use thereof as a medicine. | 2 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.