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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from German Patent Application No. 102 30 603.6 which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to a method at a spinning preparation machine, for example a cleaner, opener, carding machine or the like, for cleaning fibre material, especially cotton and further encompasses an apparatus for carrying out the method.
In a known arrangement, an examination of the nature of the trash is carried out, which examination is used for adjustment of at least one adjustable cleaning element, for example a separating blade, cleaning grid or the like.
In practice, in textile cleaning machines, especially—for example—in a pre-cleaner, the degree of cleaning is adjusted substantially with the aid of grids that can be regulated manually. This means that the amount and nature of trash material removed is dependent upon the grid positions. This also means, however, that, in the event of an incorrect adjustment, an excessive amount of good material is generally removed or else the available cleaning potential is not fully utilised. That problem arises especially when there are frequent changes of materials being processed.
In a known method (EP 0 399 315) for the operation of a system, various data have to be specified or entered into a control, including, inter alia, fibre properties, proportions of the various kinds of trash, desired degree of cleaning, production of a carded sliver. Depending on these specified data, the control is said to deliver signals by means of which adjustable opening and/or cleaning elements are so adjusted that the desired degree of cleaning and carded sliver throughput rate are achieved as a result, with any presumed fibre impairment in the cotton to be cleaned being displayed. A calculated optimisation of processing is accordingly achieved. A specific, previously entered degree of cleaning or a pre-specified throughput rate is said to be obtained. The high degree of complexity of the method is disadvantageous. In addition, it is disadvantageous that the method requires an especially high outlay in terms of system and control technology. The complexity of the method results in disruptions in the continuity of production.
SUMMARY OF THE INVENTION
It is an aim of the invention to provide a method of the type described at the beginning that avoids or mitigates the disadvantages mentioned and that especially is simple and makes possible improved and undisrupted production.
The invention provides an apparatus for cleaning fibre material at a spinning preparation machine, comprising at least one adjustable cleaning element and a control device having a memory for storing data relating to optimum adjustment of the at least one cleaning element for a specific fibre batch, the control device being in communication with at least one positioning element for effecting automatic implementation of the optimum adjustment of the at least one cleaning element when a like fibre batch is processed.
The apparatus according to the invention makes it possible, in especially simple manner, for an adjustment, once established, to be automatically reproduced again at any time. In contrast to the known method, calculated optimisation of the processing of fibre material is not carried out. For a specific fibre batch, the optimum adjustment of the cleaning element is determined in operation and stored and, when the same fibre batch is processed again, automatically retrieved. By that means, fibre material of the same provenance is optimally cleaned without loss of time and without disruption. The measures according to the invention ensure, on the one hand, that the optimum cleaning potential of the machine is always utilised and, on the other hand, that an excessive amount of good fibre material is on no account removed, or only as much as intended is removed.
Advantageously, the cleaning element is motor-adjustable. Advantageously, a trash-collecting device is provided. Advantageously, an electronic camera is associated with the trash-collecting device, which camera is in communication with an electronic evaluating unit (image-processing unit). Advantageously, determination and assessment of the trash is performed automatically. Advantageously, the evaluating device is in communication with the associated machine control. Advantageously, the optimum adjustment values are passed on to other, possibly superordinate and central systems. Advantageously, at least one opto-electronic camera is associated with each machine. Advantageously, the camera is a matrix camera. Advantageously, different light sources are provided. Advantageously, light sources of different colours are provided. Advantageously, the different colours are red light and infra-red light. Advantageously, the optimum adjustment values are used for adjusting at least one separating blade associated with a high-speed roller. Advantageously, a cleaning element is associated with a removal opening. Advantageously, the roller has a clothing. Advantageously, the at least one electronic evaluating unit (image-processing unit) is in communication with an electronic control and regulation device, for example a microcomputer. Advantageously, the machine elements such as guide vanes, separating blades and the like are automatically adjustable in dependence upon the evaluated measurement results. Advantageously, the cleaning capability of the machine is modifiable in dependence upon the evaluated measurement results. Advantageously, at least one separate camera is associated with each suction off-take location. Advantageously, a window for the camera is present in each trash-collecting line. Advantageously, a window for an illumination device is present in each trash-collecting line. Advantageously, the evaluated measurement results are used for determining the ratio of good fibre content to dirt content. Advantageously, the evaluated results are used for assessing the quality of the fibre material being processed. Advantageously, a machine is in communication with a central evaluating unit, to which more than one camera is connected. Advantageously, digital image-processing is used in the evaluating device. Advantageously, the electronic control and regulation device has, for example, a computer and a memory. Advantageously, the evaluating device is in communication with a superordinate electronic monitoring system, for example KIT. Advantageously, the measurement values of the camera are transformable into electrical signals. Advantageously, images of the trash are recorded by means of digital photodiodes. Advantageously, evaluation of the digital image information is carried out by means of image analysis software. Advantageously, the machine is in communication, by way of a communications network, with a central superordinate system control. Advantageously, in a case of repetition of a specific fibre batch for the stored pre-adjustment of cleaning elements, a visual checking device is associated with the camera system.
Advantageously, in a case of repetition of a specific fibre batch for the stored pre-adjustment of cleaning elements, a correction device for the adjustment is associated with the camera system. Advantageously, for checking, the stored data are compared with the current data. Advantageously, a malfunction or warning signalling device is activatable if there are discrepancies on comparison. Advantageously, the cleaning devices are adjusted until there is a match between stored and current data. Advantageously, current data are entered into the memory if there are discrepancies with stored data. Advantageously, a device that shields against trash, for example a deflecting plate, is associated with the camera. Advantageously, a device for an even level of trash, for example a light barrier, is provided. Advantageously, the spacing between the camera and the surface of the collected trash is the same. Advantageously, the positioning element for adjustment of the cleaning element is an electric motor. Advantageously, the electric motor is a stepper motor.
The invention also provides a method at a spinning preparation machine, for example a cleaner, opener, carding machine or the like, for cleaning fibre material, especially cotton, wherein an examination of the nature of the trash is carried out, which examination is used for adjustment of the at least one adjustable cleaning element, for example a separating blade, cleaning grid or the like, characterised in that the optimum adjustment of the at least one cleaning element for a specific fibre batch is stored in a memory of an electronic control and regulation device and, when the same fibre batch is processed again, the optimum adjustment of the cleaning element is implemented automatically. Advantageously, the optimum adjustment of the cleaning elements is determined manually. Advantageously, the optimum adjustment of the cleaning elements is determined automatically. Advantageously, the examination of the trash (trash composition) is performed visually. Advantageously, the examination of the trash (trash composition) is performed opto-electronically, for example by means of a camera. Advantageously, the optimum adjustment is determined by repeated readjustment of the cleaning elements on the basis of the examination of the trash (trash composition). Advantageously, the optimum adjustment of the cleaning elements is determined once. Advantageously, the cleaning element is motor-adjusted.
The apparatus preferably comprises a said adjustable cleaning element a grid having grid elements which are adjustable for adjusting the degree of cleaning.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a diagrammatic side view of a cleaning machine having the apparatus according to the invention (motorised grid adjustment);
FIGS. 1 b , 1 c is a partial side view of the grid bars according to FIG. 1 a , having relatively wide ( 1 b ) and narrow ( 1 c ) grid gaps;
FIG. 2 is a block diagram of an electronic control and regulation device and connected camera, image-evaluating unit, operating and display unit, positioning motors and grid-adjusting elements;
FIG. 3 is a block diagram as in FIG. 2 , but without an electronic camera system;
FIG. 4 is a diagrammatic representation of a production line in which the invention is implemented, having a plurality of machines coupled by way of a network and a central system control;
FIG. 5 is a side view of cleaning apparatus having a camera for trash monitoring, in accordance with a first arrangement; and
FIG. 6 is a side view of cleaning apparatus having a camera for trash monitoring, in accordance with a further arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 a , a double-roller cleaning machine 1 (axial cleaner), for example a MAXI-FLO MFC cleaner made by Trutzschler GmbH & Co of Mönchengladbach, Germany, has two rotating opener rollers 2 a , 2 b , underneath which there are arranged grids 3 a , 3 b having through-holes. The opener rollers 2 a , 2 b rotate anti-clockwise, in accordance with arrows A, B. The supply of the fibre material to be cleaned and the removal of the cleaned fibre material is analogous to that shown diagrammatically in FIGS. 5 and 6 . Underneath the grids 3 a , 3 b there is a trash-collecting unit 4 , which has a pneumatic trash-removing line 5 . Fixed to the circumference of the opener rollers 2 a , 2 b are beater spikes 2 ′, 2 ″, which pass the supplied fibre flocks over the cleaning bars 3 1 to 3 n of the cleaning grids 3 a , 3 b , which are arranged around part of the circumference of the opener rollers 2 a , 2 b . The position of the grid bars 3 1 to 3 n (cleaning bars) is adjustable (see FIGS. 1 b , 1 c ) so that, as a result, the intensity of cleaning is modified. The grid bars 3 1 to 3 n are mounted, in the region of their bottom end, in regulating plates 6 a , 6 b , which can be adjusted by means of electric motors 7 a , 7 b (stepper motors). In this arrangement, the grid bars 3 1 to 3 n are collectively held in the grids 3 a , 3 b in such a manner that, by means of one motor 7 a or 7 b , all the grid bars 3 1 to 3 n in a respective group are rotated about their axes together. In the case of this adjustable bar grid 3 a , 3 b , the edge directed towards the opener roller 2 a , 2 b is sharp, the tip being positioned counter to the direction of rotation A or B.
In accordance with FIGS. 1 b , 1 c , each grid bar 3 1 to 3 n has, at its two ends, two cylindrical projections 3 ′, 3 ″ (pins). The pins 3 ′ are fixedly mounted in a holder 8 and form the pivot point for the grid bars 3 1 to 3 n . Rotation is brought about at the pins 3 ″ by means of the regulating plates 6 a and 6 b , which are rotatable about the axes of the opener rollers 2 a and 2 b , respectively, and which are actuated by the motors 7 a and 7 b , respectively, in the direction of arrow C (or, as the case may be, in the opposite direction D). FIG. 1 b shows the grid 3 a in the fully open state; the gaps in the grid are then open to their widest extent. The sharp edge of the grid bar is at its closest setting with respect to the roller 2 a so that the action is at its strongest. By rotating the regulating plate 6 a from the position of the bars 3 1 to 3 n according to FIG. 1 b into the position according to FIG. 1 c , the gap becomes narrower; gradually, the sharp edge is lowered in a tangential direction so that its action becomes less and less. This apparatus provides the possibility of adjusting the grid 3 a in accordance with the desired action.
In the embodiment of FIG. 2 , a camera 12 , for example a CCD camera is provided for examining separated trash. The camera 12 , an operating and display unit 13 , and the positioning motors 7 a , 7 b for adjustment of the regulating plates 6 a , 6 b are connected, by way of an image-evaluating device 11 , to an electronic control and regulation device 10 (machine control), for example a microcomputer. The control and regulation device 10 is in communication with a system control 14 having an operating and display unit 15 . Reference numeral 9 denotes a memory associated with the control and regulation device 10 . The optimum adjustment of the cleaning grids 3 a , 3 b for a specific fibre batch is stored in the electronic memory 9 .
FIG. 3 shows an embodiment which is similar to that of FIG. 2 except that no camera is present. The operating principle for regulation of the grids 3 a , 3 b is shown. Reference numbers 9 , 10 , 13 , 14 and 15 have the meanings given above with reference to FIG. 2 . Reference numeral 22 denotes a memory which is associated with the system control 14 . In this arrangement, the memory 22 is intended for storing the optimum adjustment of at least one cleaning element 3 a , 3 b for a specific fibre batch.
In accordance with FIG. 4 , a plurality of machines, for example MFC cleaners of the kind already mentioned, are coupled, by way of a network 16 , to the central system control 14 . As machine control 10 a , 10 b and as system control 14 there may be provided a TMS-2 microcomputer control manufactured by Trutzschler GmbH & Co. KG of Mönchengladbach, Germany. The memories 9 and 22 (see FIG. 3 ) are not shown separately; they are integrated into the control devices 10 a , 10 b and 14 . Reference numeral 15 indicates an operating and display unit for system control 14 , and reference numerals 13 a , 13 b indicate operating and display units for respective machine controls 10 a , 10 b.
Regulation of the grids is carried out by means of the motors 7 a , 7 b , which are controlled by the control 10 of machine 1 . In dependence upon optimum adjustments established on one occasion for the various materials and stored in the control 10 , these adjustments can be automatically produced again at any time, when required. All that is needed therefore is an entry indicating which material 17 is being processed. When such a machine 1 is connected, by way of a network 16 , to a superordinate system control 14 (see FIG. 4 ), it is also possible for such data to be specified from there in fully automatic manner. In such a case, the optimum adjustments, once determined, are transferred from the machine 1 to the said control, where they are stored. In the event of a change of material, a large number of adjustments including, in accordance with the invention, the positions of the grids 3 a , 3 b are usually transferred from the system control 14 to the individual machines 1 .
Analysis of the trash 19 ″ removed, which is, to a very large extent, automatic, may be achieved by mounting one or more electronic camera systems 12 , together with illumination, in the machine 1 so that automatic assessment of the trash is possible. When such a device is appropriately configured, it is possible, for example, to determine an optimum trash composition for each material, to record images thereof and to store the images and subsequently, when required, to regulate the grids 3 a , 3 b until the earlier images approximately match the current images. Consequently, the composition of trash 19 specified earlier is then to a very large extent re-established automatically and incorrect adjustments in all respects are substantially avoided.
If it is possible for the technological conditions relating to the good material 17 and the optimum trash 19 associated therewith to be formulated in terms of graphics or formulae, specific data for various materials pre-determined by the manufacturer can also be stored in the system, which data will then no longer need to be determined first at the customer's premises but can be retrieved directly. A further simplification is possible as a result.
An illustrative method according to the invention and the mode of operation of an above-described apparatus according to the invention may be described as follows:
1. The pre-cleaners 1 (e.g. MFC) have cleaning elements 3 1 to 3 n capable of motorised regulation. The adjustable motors 7 a , 7 b are controlled by the control 10 present in the machine 1 . 2. The operator observes the trash 19 being produced during operation of the machine 1 . If required, he regulates the cleaning elements, for example by means of the operating keyboard of the operating and display unit 13 of the machine 1 , until the trash composition corresponds to his wishes. He then reports to the machine control 10 , by means of the keyboard 13 , that the composition of trash currently being produced precisely corresponds to that which he desires. 3. In addition, the operator also reports to the control 10 the material 17 (or batch) to which this adjustment applies. 4. The machine control 10 then notes (memory) the positions of the regulating motors 7 a , 7 b and the batch to which this adjustment belongs. 5. The procedures described under points 2 to 4 are normally necessary once for each individual batch. 6. Subsequently, whenever the batch in question is processed again, it is necessary only to report to the machine control 10 that this batch is now being processed. 7. That reporting may be performed by the operator. 8. It is, however, preferable for the machine to be connected, by way of a communications network 16 , to a central, superordinate system control 14 ( FIGS. 3 and 4 ) and for the established adjustments and the associated batch name (see point 4 ) also to be reported, by way of the network, to the system control 14 and stored there. In this case, it is possible subsequently for the correct adjustment to be specified fully automatically, at any time, from that central location. 9. The method described above can be improved by additionally installing opto-electronic camera systems which are capable of assessing the trash 19 located in the trash compartment of the machine 1 . 10. At the moment when the operator determines that the trash corresponds to his wishes and he reports that to the control (see point 2 ), the cameras 12 record one or more images of the trash 19 ; these images are evaluated by the control 10 and the determined data are stored together with the positions of the grids 3 a , 3 b and the relevant batch (see also points 2 to 4 ). Points 5 to 8 are equally valid when camera systems are used. 11. When camera systems are used, it is also possible, in a case of repetition of a specific batch for the stored pre-adjustment of cleaning elements, to carry out, in addition, visual checks and even, where required, corrections to the adjustment. 12. The checks are performed by comparing the stored data of the earlier images with the current image data. 13. If discrepancies are found during that comparison, that fact can be displayed in the form of a malfunction or warning signal (for example on the display of the operating and display unit 13 ). 14. In addition, it is also possible to regulate the cleaning elements 3 1 to 3 n until a match is obtained.
Such discrepancies may come about despite the fact that, in a case of repetition, the same material is being processed again. This is due to the fact that the material being processed is a natural product, which always is subject to certain variations in respect of consistency, colour, dirt content etc. A method according to the invention is accordingly capable of automatically carrying out reproducible adjustments and also, moreover, of automatically recognising material-specific variations and making a correction.
15. If corrections are made with respect to the originally determined adjustments, those new adjustments can likewise be stored and then, on the next change-over, can again be taken as guide values.
By this means, a continuous and automatic process of adaptation to the product in question can be carried out.
In the embodiment of FIG. 5 , a cleaner is of generally similar construction to that of FIG. 1 a and parts indicated by reference numerals 2 a , 2 b , 3 a and 3 b have the meanings given with reference to FIG. 1 a . Arrows 17 , 18 indicate the movement of fibre material into and away from cleaner 1 . A transparent window 23 is arranged in a side wall of the trash-collecting device 4 , through which window the electronic camera 12 records, from the outside, the trash 19 ″ which has been collected in the internal space 21 . Two illumination devices 20 a , 20 b are associated with the camera 12 . Reference numeral 25 indicates a roller for assisting in the feeding of collected trash 19 ′″ for discharge as indicated by arrow 19 ′″
In the embodiment of FIG. 6 , the construction is the same as that of the machine in FIG. 5 except that the camera 12 , including the illumination devices (not shown), is arranged inside the internal space 21 , behind a protective covering 24 . In both FIGS. 5 and 6 , reference numeral 25 denotes a discharge roller. In both FIGS. 5 and 6 , reference numeral 19 ′ denotes the trash dropping down from the grids 3 a , 3 b , through the space 21 ; reference numeral 19 ″ denotes the trash collected at the bottom end of the trash-collecting device 4 ; and 19 ′″ denotes the trash discharged, and preferably drawn off under suction, from the trash-collecting device 4 .
Depending on which camera position is selected (for example, in accordance with FIG. 6 ), a device will typically be provided which ensures that the level of trash 19 ″ remains the same, for example a light barrier or any other form of device suitable for maintaining and controlling the trash level. This may be necessary because the cameras 12 usually have only a limited depth of field. | In a method at a spinning preparation machine, for example a cleaner, opener, carding machine or the like, for cleaning fiber material, especially cotton, an examination of the nature of the trash is carried out, which examination is used for adjustment of at least one adjustable cleaning element, for example a separating blade, cleaning grid or the like.
In order to make possible improved and undisrupted production by simple means, the optimum adjustment of the at least one cleaning element for a specific fiber batch is stored in a memory of an electronic control and regulation device and, when the same fiber batch is processed again, the optimum adjustment of the cleaning element is implemented automatically. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 09/318,933, filed May 26, 1999, U.S. Pat. No. 6,222,971 and entitled “SMALL INLET OPTICAL PANEL AND A METHOD OF MAKING A SMALL INLET OPTICAL PANEL”, which is a continuation-in-part of U.S. patent application Ser. No. 09/118,270, filed Jul. 17, 1998, and entitled “SMALL INLET OPTICAL PANEL”, now abandoned.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with Government support under contract number DE-AC02-98CH10886, awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed generally to a planar optical display, and, more particularly, to a small inlet optical panel and a method of making a small inlet optical panel.
2. Description of the Background
It is known in the art to form an optical panel from a plurality of stacked waveguides. The waveguides collectively define an inlet face at one end of the waveguides and an outlet face at an opposite end. The outlet face may be disposed obliquely with the inlet face. The outlet face may form an small acute face angle with the longitudinal axes of the waveguides, thus allowing the height of the screen to be substantially larger than the depth or thickness of the panel. The panel inlet face generally extends the fill width of the panel correspondent to the width of the outlet face, but is very narrow due to the thinness of the panel. For example, where an inlet face has a width of 133 cm, the corresponding length in the prior art would be 2.54 cm.
The narrow inlet face necessitates the use of a complex light projection system for distributing and focusing the image light across the full width and depth of the panel, thereby allowing for accurate display on the outlet face. This complex light projection system increases the complexity and cost of the overall system, and increases the space requirements of the display panel.
Therefore, the need exists for a waveguide optical panel having an aperture inlet which allows for simplification of light projection and focusing at the inlet, without a loss of image resolution at the outlet face.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a small inlet optical panel, which includes a first plurality of stacked optical waveguides which forms an outlet face body with an outlet face, which includes a second plurality of stacked optical waveguides which forms an inlet face body with an inlet face, and an optical coupling element connected to the first plurality and to the second plurality, wherein the optical coupling element redirects light along a parallel axis of the inlet face to a parallel axis of the outlet face. In the preferred embodiment of the present invention, the inlet face is disposed obliquely with and askew from the outlet face.
The present invention is also directed to a method of making a small inlet optical panel which includes individually coating a plurality of glass sheets in a substance having an index of refraction lower than that of the glass sheets, stacking the plurality of coated glass sheets, wherein each coated glass sheet is fastened to an adjoining glass sheet using an adhesive, applying pressure to the stack, curing the adhesive, cutting the stack to form an outlet face body having a first wedge shape with an outlet face thereon, repeating the individually coating, the stacking, the applying and the curing to form a second stack, cutting the second stack to form an inlet face body having a second wedge shape correspondent to the first wedge shape and having an inlet face thereon, and joining together the inlet face body and the outlet face body at an optical coupling element, wherein the outlet face is disposed askew from the inlet face, for redirecting light incident into the inlet face body to a direction incident into the outlet face body.
The present invention solves difficulties encountered in the prior art by providing a waveguide optical panel having a small aperture inlet, which allows for simplification of light projection and focusing at the inlet, without a loss of image resolution at the outlet face.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For the present invention to be clearly understood and readily practiced, the present invention will be described in conjunction with the following figures, wherein:
FIG. 1 is an isometric view schematic illustrating a small inlet optical panel;
FIG. 2 is an isometric view schematic illustrating a horizontal and vertical cross-section of a small inlet optical panel;
FIG. 3 is a schematic illustrating an exaggerated horizontal and vertical cross-section of the-small inlet optical panel;
FIG. 4 is a horizontal and vertical cross section of the small inlet optical panel illustrating an alternative embodiment of the panel using one plurality of waveguides;
FIG. 5 is an isometric view schematic illustrating an alternative embodiment of the small inlet optical panel which includes an optical coupler in the form of a holographic optical element;
FIG. 6 is an isometric view schematic illustrating an alternative embodiment of the small inlet optical panel wherein the inlet face is coplanar with the outlet face; and
FIG. 7 is an isometric view schematic illustrating an alternative embodiment of the small inlet optical panel wherein the inlet face is opposite the outlet face.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, many other elements found in a typical optical display panel. Those of ordinary skill in the art will recognize that other elements are desirable and/or required in order to implement the present invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
FIG. 1 is an isometric view schematic illustrating a small inlet optical panel 10 . The display panel 10 includes an inlet face 12 for receiving light 14 , and an outlet face 16 disposed obliquely with and askew from the inlet face 12 for displaying light 14 . The light 14 is generated by a light generator 17 . The inlet face 12 and outlet face 16 are each formed by a plurality of waveguides 12 a , 16 a , wherein one end of each waveguide 12 a , 16 a forms an inlet for that waveguide 12 a , 16 a , and wherein the opposite end of each waveguide 12 a , 16 a forms an outlet for that waveguide 12 a , 16 a.
The inlet face 12 is preferably disposed generally perpendicular to and askew from the outlet face 16 for receiving the light 14 from the modulator 20 and projector 22 . The horizontal extension of each waveguide 12 a of the inlet face 12 is disposed below and substantially perpendicular to the horizontal extension of each waveguide 16 a of the outlet face 16 . The plurality of stacked waveguides 12 a of the inlet face 12 extends vertically.
Each waveguide 16 a extends horizontally, and the plurality of stacked waveguides 16 a extends vertically, along the outlet face 16 . The light 14 is displayed on the outlet face 16 in a form such as, but not limited to, a video image 14 a The outlet face 16 may be generally formed into a triangular wedge having an acute face angle A between the bottom 30 of the body 32 of the outlet face 16 and the back 34 of the body 32 of the outlet face 16 . The acute face angle A may be in the range of about 5 to 10 degrees, for example, with the panel 10 increasing in thickness from a minimum at the top 36 of the body 32 of the outlet face 16 , to a maximum thickness at the bottom 30 of the body 32 of the outlet face 16 . The maximum thickness may be chosen as small as is practicable in a given application. The panel 10 has a height from the top to the bottom of the outlet face 16 , and a width from the left to the right of the outlet face 16 . The width and height may be selected to produce width to height aspect ratios of 4:3 or 16:9, for example, for uses such as a typical television application. In an exemplary embodiment of the outlet face 16 of the present invention, a maximum thickness in the range of about 8 cm may be chosen, in conjunction with a height of 100 cm and a width of 133 cm. The left to right width of the inlet face 12 is chosen to be the same as the maximum thickness T of the panel 10 . The inlet face 12 has a suitable vertical height h, which is a matter of design choice. The inlet face 12 has a width to height aspect ratio which, for the purpose of ease of interface with the outlet face 16 , is preferably also 4:3. Correspondingly, the panel 10 diverges in two wedge shapes, one from the bottom 30 to the top 36 of the outlet face body 32 , and the second at the bottom 30 of the outlet face body 32 , from the left of the interface 40 to the inlet face 12 .
The disposition of the inlet face 12 with the outlet face 16 necessitates the redirection of the light 14 , which light 14 is incident on the inlet face 12 in an approximately horizontal plane and must be redirected to a vertically upwardly direction through the waveguide 16 a of the outlet face 16 . This periscopic optical path permits the use of a relatively small area modulator 20 at the bottom of the panel 10 to provide a small aperture light source which is expanded through the panel 10 for display on the outlet face 16 at a substantially increased viewing area.
The light generator 17 generates light 14 and passes the light 14 to inlet face 12 , and the surface area of light generation immediately adjacent to the inlet face 12 preferably is equivalent to the surface area of the inlet face 12 . The light generator 17 may include a light source 22 , a light modulator 20 , or imaging optics. The light 14 may be initially generated by the light source 22 . The light source 22 may be, for example, a bright incandescent bulb, a laser, a plurality of phosphors, at least one LED, at least one OLED, at least one FED, or a projector. The light 14 from the source 22 is preferably collimated. The light 14 may be modulated by the modulator 20 for defining individual picture elements, known in the art as pixels. The modulator 20 may take a form known in the art, such as, but not limited to, a liquid crystal display (LCD), a Digital Micromirror Device (DMD), a GLV, a raster scanner, a vector scanner, a PDLC, an LCOS, a MEMS, and a CRT. The imaging optics may include light folding mirrors or lenses. The imaging optics may be optically aligned between the inlet face 12 and the light modulator 20 for compressing or expanding and focusing the light 14 as required to fit the inlet face 12 . The modulated light 14 is generally incident on the inlet face 12 from the imaging optics as a compressed image which is transmitted horizontally through the inlet face 12 , turned for transmission vertically upwardly through the outlet face body 32 for display, and expands for suitable horizontal and vertical resolution and scale.
FIG. 2 is an isometric view schematic illustrating a horizontal and vertical cross-section of a small inlet optical panel 10 of FIG. 1 . The panel 10 includes a first, or top, plurality of stacked optical waveguides 16 a forming an outlet face 16 , a second, or bottom, plurality of stacked waveguides 12 a stacked perpendicularly to the outlet face 16 to form an inlet face 12 below the bottom 30 of the body 32 of the outlet face 16 , and a light redirection element 50 disposed inside the panel 10 at the interface 40 between the inlet face waveguides 12 a and the outlet face waveguides 16 a for redirecting the light 14 for periscopic transmission through the waveguides 12 a , 16 a.
The waveguides 12 a , 16 a are configured in two independent groups with the first plurality of waveguides 16 a forming a wedge defining the outlet face 16 and the interface 40 . The second plurality of waveguides 12 a are disposed below the light redirection element 50 at the interface 40 , and forms a wedge defining the inlet face 12 . The second plurality of waveguides 12 a are configured in a wedge correspondent to the wedge shape of the outlet face body 32 . The body 32 of the outlet face 16 wedge receives the light 14 for transmission vertically upwardly to the outlet face 16 . The body 32 of the outlet face 16 receives light 14 to along the surface of the bottom 30 of the body 32 , adjacent the light redirection element 50 . The light 14 received at the bottom 30 of the body 32 is passed through the body 32 , and is displayed on the outlet face 16 . The body 60 of the inlet face 12 wedge receives the light 12 at its vertical inlet face 12 for transmission substantially horizontally to emission at the light redirection element 50 . The inlet face 12 may be sized to match the area of the modulator 20 for receiving the light 14 , and the inlet face 12 is also substantially smaller in area than the interface 40 at the light redirection element 50 . The angle A of the outlet face 16 wedge may be about 5 to 10 degrees, and the second angle B of the inlet face 12 wedge is then be suitably smaller.
The plurality of stacked waveguides 12 a , 16 a used to form the inlet face 12 and the outlet face 16 may be formed of any material known in the art to be suitable for passing electromagnetic waves therethrough, such as, but not limited to, glass, plastics, polymers. The preferred embodiment of the present invention is implemented using individual glass sheets, which are typically approximately 2-40 microns thick. Two different thicknesses of glass sheet may be used simultaneously in a given application of the present invention, one to form the outlet face 16 , and one to form the inlet face 12 . In the preferred embodiment of the present invention, the glass sheets used within the inlet face 12 are approximately the same thickness, and the glass sheets used within the outlet face 16 are approximately the same thickness. The glass used may be of a type such as, but not limited to, glass type BK-7, or may be a suitable plastic laminate, such as Lexan®, commercially available from the General Electric Company®. The waveguides 12 a , 16 a are discussed with more particularity with respect to FIG. 3 .
The light redirection element 50 is disposed between the body 60 of the inlet face 12 and the body 32 of the outlet face 16 . The light redirection element 50 may be, for example, an optical coupling element, and may be fastened to each plurality of waveguides 12 a , 16 a using methods known in the art, such as an optically transparent epoxy. The function of the coupler 50 is to redirect the initially horizontally directed light 14 from the bottom plurality of waveguides 12 a vertically upwardly into the top plurality of waveguides 16 a . Both the waveguides 12 a , 16 a and the coupler 50 of the present invention are passive optical devices. The light redirection element 50 is discussed with more particularity with respect to FIG. 3 .
FIG. 3 is a schematic illustrating an exaggerated horizontal and vertical cross section of the small inlet optical panel 10 embodied in FIG. 2 . The light redirection element 50 redirects the light 14 flowing into the inlet face 12 , which then flows through the bottom plurality of waveguides 12 a and is thereby incident on the light redirection element SO, to flow into the top plurality of waveguides 16 a , and thereby be incident on the outlet face 16 . The light redirection element 50 preferably includes a plurality of fresnel prismatic grooves 50 a which are straight along the width of the bottom waveguides 12 a in the direction of the panel thickness T for redirecting the image light 14 vertically upwardly into the top plurality of waveguides 16 a . In a preferred embodiment, the light redirection element 50 is an optical coupler 50 in the form of a Transmissive Right Angle Film (TRAF) II, which is commercially available from the 3M Company of St. Paul, Minn. The TRAF II coupler 50 is effective for turning the image light at an angle of up to approximately 90°. In an alternative embodiment of the present invention, the light redirection element 50 may be in the form of a diffractive grating 50 , which diffractive grating 50 includes an extremely small series of straight gratings configured for optically diffracting the light 14 in order to turn the light flowing substantially horizontally through the bottom plurality of waveguides 12 a vertically upwardly into the top plurality of waveguides 16 a . The diffractive grating 50 has a lower turning angle capability than the TRAF II embodiment.
An individual waveguide 12 a , 16 a used in the present invention typically includes a cental core 100 laminated between cladding layers 102 , a receiving end 104 , and an outlet end 106 . The central core 100 channels the image light 14 through the waveguide 12 a , 16 a , is disposed between cladding layers 102 , and extends from the receiving end 104 to the outlet end 106 . The central core 100 is, in the preferred embodiment, a glass sheet of thickness T in the range between 2 and 40 microns, as discussed hereinabove. The central core 100 has a first index of refraction. The cladding layers 102 also extend from the receiving end 104 to the outlet end 106 . The cladding layers 102 may be black in color to improve contrast and brightness. Alternatively, a black layer maybe disposed between adjoining cladding layers 102 for absorbing ambient light at the outlet end 106 , where the adjoining cladding layers 102 are transparent. The term black is used herein to encompass not only pure black color but additionally, any functionally comparable dark color suitable for use in the present invention, such as dark blue. The cladding layers 102 have a second index of refraction, lower than that of the central core 100 , for ensuring total internal reflection of the image light 14 as it travels from the receiving end 104 to the outlet end 106 .
The top plurality 16 a and the bottom plurality 12 a of stacked waveguides may be made by several methods. A plurality of glass sheets may be individually coated with, or dipped within, a substance having an index of refraction lower than that of the glass, and a plurality of coated sheets may then be fastened together using glue or thermally curing epoxy. Alternatively, the glue or epoxy could form the cladding layers and be applied directly to the glass sheets. In one embodiment of the present invention, a first coated or uncoated glass sheet is placed in a trough sized slightly larger than the first coated glass sheet, the trough is filled with a thermally curing black epoxy, and the coated or uncoated glass sheets are repeatedly stacked at an angle, forming a layer of epoxy between each coated or uncoated glass sheet. The stacking is preferably repeated until between approximately 500 and 800 sheets have been stacked. The number of waveguides 16 a which are stacked to form the outlet face 16 are selected for providing a corresponding vertical resolution of the outlet face 16 . For example, 525 of the waveguides 16 a may be stacked in the outlet face 16 to produce 525 lines of vertical resolution in the outlet face 16 . Uniform pressure may then be applied to the stack, followed by a cure of the epoxy, and a sawing of the stack into a wedge shape of an angle dependant on the use of the stack as an outlet face 16 or an inlet face 12 . The wedge may be sawed curved or flat, and may be frosted or polished after sawing.
FIG. 4 is a horizontal and vertical cross section of the small inlet optical panel 10 illustrating an alternative embodiment of the panel 10 . In this alternative embodiment, the top plurality of waveguides 16 a extend vertically, continuously from the outlet face 16 to the side inlet face 12 , with the interface 40 being horizontal and disposed at the bottom edge 30 of the outlet face 16 .
In this alternative embodiment, the light redirection element 50 c , is disposed at the bottom of the panel 10 and is inclined from the inlet face 12 at the right side of the outlet face 16 to the opposite side of the outlet face 16 . The bottom of the plurality of waveguides 16 a , as well as the element 50 c , are therefore inclined at the small acute angle B from the bottom of the panel 10 , thereby defining a bottom wedge portion. Also in this alternative embodiment, the element 50 c includes a plurality of tilted reflective facets or mirrors 50 c optically aligned between the inlet face 12 and the interface 40 for reflecting the substantially horizontally directed light 14 vertically upwardly to the outlet face 16 .
FIG. 5 is an isometric view schematic illustrating an alternative embodiment of the small inlet optical panel 10 , and includes a light redirection element 50 d in the form of a holographic optical element 50 d configured to reflect the image light 14 from the inlet face 12 across the interface 40 for display on the outlet face 16 . The holographic coupler 50 d may take a conventional form known in the art for turning the light 14 from a substantially horizontal direction to the vertical direction required for internal transmission through the top plurality of waveguides 16 a to the outlet face 16 .
FIG. 6 is an isometric view schematic illustrating an alternative embodiment of the small inlet optical panel 10 , including a top plurality of waveguides 16 a configured as in the above embodiments. The alternative embodiment of FIG. 7 also includes a bottom plurality of waveguides 12 a which are continuous along the full width W of the outlet face 16 and are stacked vertically. In this embodiment, the inlet face 12 extends the full width W of the outlet face 16 directly below the outlet face 16 at the front of the panel 10 .
FIG. 7 is an isometric view schematic illustrating an alternative embodiment of the small inlet optical panel 10 , wherein the inlet face 12 extends the full width W of the outlet face 16 , but is disposed at the back of the panel 10 .
Those of ordinary skill in the art will recognize that many modifications and variations of the present invention may be implemented. The foregoing description and the following claims are intended to cover all such modifications and variations. | An optical panel having a small inlet, and a method of making a small inlet optical panel, are disclosed, which optical panel includes a individually coating, stacking, and cutting a first plurality of stacked optical waveguides to form an outlet face body with an outlet face, individually coating, stacking, and cutting a second plurality of stacked optical waveguides to form an inlet face body with an inlet face, and connecting an optical coupling element to the first plurality and second plurality of stacked optical waveguides, wherein the optical coupling element redirects light along a parallel axis of the inlet face to a parallel axis of the outlet face. In the preferred embodiment of the present invention, the inlet face is disposed obliquely with and askew from the outlet face. | 8 |
FIELD OF THE INVENTION
The invention relates to a paving stone with lateral spacers adapted to be arranged in a paving stone bond in an area-covering grid-shaped lattice of paving stones comprised of lattice elements.
BACKGROUND OF THE INVENTION
A wide variety of paving stones have become known up to now. For example, DE 31 16 540 and U.S. Pat. No. 3,494,266 describe paving stones whose outer contour is shaped in such a way that they can mesh with neighboring stones.
By this meshing, they are secured against lateral displacement, as a result of which the stability of a paving stone bond laid from such paving stones is increased.
In the case of such stones, although the stability of the paving stone bond is improved by the positive meshing, joints running right through, in which for example grass or moss can grow for decorative purposes, are not possible. In addition, the rainwater cannot seep very well down into the ground through such a positively joined-together paving stone bond.
To combine the advantages of meshing teeth in the outer contour with the advantages of intermediate joints, a stone such as that described in EP 0 060 961 B1 was created.
This stone again has in its lower region an outer contour for meshing with neighboring stones, but in its upper third is stepped with respect to the lower region. The upper third has a quadrangular outer shape, which has a smaller extent than the lower meshed region. On the upper side of this quadrangular stepped region there is the walk-on face.
If such a stone is laid in a bond, it is secured by the meshing teeth in its lower region against lateral displacement and in the upper region there is sufficient space for forming joints.
However, in such a bond of stones there is the disadvantage that water cannot seep very well into the ground underneath on account of the outer contours in the lower region engaging positively in one another over their entire extent.
On the other hand, paving stones with lateral spacers for forming uniform joints between the individual paving stones have also become known already in a variety of instances. Such stones are described, for example, in DE 89 01 920, DE 87 00 821, EP 0 227 144 and DE 83 02 622.
In the case of all these configurations, the spacers are designed such that, during laying in a bond of stones, they are made to abut against only correspondingly abutting sides parallel to the side walls of the paving stones. They thereby abut either against the corresponding abutting faces of the spacers or of the side walls of neighboring stones.
Although such spacers provide the desired spacing between the side walls of the stones, they do not provide the latter with any additional hold with respect to a displacement parallel to the side walls.
DE 89 13 777 describes a paving stone with spacers in which the spacers have sloping, non side-parallel abutting faces for securing the stones against lateral displacement.
Although such a paving stone is adequately anchored against lateral displacement in its paving stone bond, such a stone has stone sides having varying designs, even in the case of a square outline. This means increased effort both during the production of such a stone and during laying in a paving stone bond, which entails a corresponding increase in costs in the case of both operations.
Finally, a paving stone with spacer which has in each case an outer structure serving for positive connection has become known from DE 90 00 928-U or DE 38 04 760 A1. These structures are, however, arranged in a complicated manner, in particular in the case of the first-mentioned document, and require extremely precise laying of these stones, which particularly in the case of machine laying does not occur.
The invention therefore has the object of proposing a paving stone with which on the one hand the formation of uniform joints and unproblematical seeping away of water are ensured and on the other hand, however, anchorage with regard to lateral displacement of the paving stone occurs, while at the same time to said stones are easy to lay.
SUMMARY OF THE INVENTION
On the basis of a paving stone of the above-mentioned type, the object of the invention is achieved by a paving stone having side walls and comprising a plurality of spacers disposed on the side walls thereof. Each of the spacers has an abutting surface adapted to be positively joined to a respective abutting surface of a spacer on an adjacent paving stone in the lattice of paving stones. In this manner, a crossing joint is formed between the paving stones. The abutting surface of each of the spacers includes a stepped contour for positively meshing with a corresponding stepped contour on the respective abutting surface of the spacer on the adjacent paving stone, the plurality of spacers being disposed on the side walls of the paving stone such that the stepped contours of their respective abutting surfaces are configured similarly in either of two rotational directions defined around the side walls of the paving stone.
Advantageous further developments and configurations of the invention are possible as will be described further below.
Accordingly there is provided a paving stone for fitting into a paving stone bond, which is divided into an area-covering, grid-shaped lattice and is provided with lateral spacers which have in each case a preferably stair-shaped or stepped abutting face for positive fitting onto a complementary abutting face of a spacer of a neighboring stone. The abutting face of each spacer consequently has a spatial structure which serves for meshing with the complementary abutting face of a spacer of a neighboring stone, the stepping of the abutting faces on a paving stone taking place in the same rotational direction.
Paving stones designed in such a way are firmly anchored, even with regard to lateral displacements, by the positive meshing of the spacers with one another in a paving stone bond. The stability, and consequently the loadability, of a paving stone bond joined together from such stones is distinctly increased as a result of the above configuration.
In addition, in the case of a stone shape according to the invention, the advantages in the use of spacers are retained, i.e. the seeping of water through the existing joints is ensured at all times with uniform joint widths. The joint between the paving stones may, furthermore, be decoratively fashioned in virtually any desired way in a manner corresponding to the respective intended use. Thus, for example, the shape of the joint is not in any way restricted to straight edges. Rather, the borders of the paving stones may, as desired, be curved, serrated or provided with other shapings.
In a preferred embodiment, two or more spacers are provided on one paving stone side and the same number of spacers are provided with equal spacing with respect to one another on the complementary side of the adjacent paving stone. This offers the advantage that a so-called cross bond can be laid at any time with a single type of paving stone. The spacers of one side and the associated complementary side are arranged such that for each spacer there is a complementary spacer and that all of these pairs of spacers can simultaneously engage positively in one another.
To be able, if appropriate, to lay a decorative pattern in a mosaic-like manner into a paving stone bond, paving stones of various sizes are necessary. In such cases, use is advantageously made of paving stone sizes which in each case occupy an integral number of lattice elements in the grid-shaped lattice of the paving stone bond.
Particularly favorable for forming an area-covering lattice grid is a stone which, apart from the spacers, has the outline of a parallelogram. The individual lattice elements of the lattice grid may then likewise be provided by parallelograms with sides in each case extended with respect to the paving stone by half a joint width to both ends of the paving stone.
If, for example, the spacers to be assigned to each of two opposite sides are arranged at the same height along their side walls, an alignment of the paving stones in a so-called cross bond without offset between the neighboring stones in a straight alignment is possible. This also applies, of course, if the lattice lines do not cross at 90°.
Preferably, two or more spacers of the same side wall are provided with the same abutting faces and are attached at the same distance from this side wall. The distance of these abutting faces from one another in the longitudinal direction of their side wall is in this case chosen such that it is equal to the length of one lattice element divided by the number of spacers provided per lattice element.
Such a paving stone may be arranged in a so-called stretching bond, in which the paving stones of one row have an offset with respect to the next row. In the case of a paving stone bond with only stones of the same size, the number of spacers designed as described above of a side wall determines the number of offset possibilities in the direction of this side wall.
If two opposite side walls of a paving stone according to the invention are designed symmetrically with respect to a rotation of the stone through 180°, this on the one hand reduces the effort during production of the stone and on the other hand permits the fitting of a stone into a bond in two orientations. This is advantageous in particular in the case of a rectangular paving stone, since it is possible in this case to join the paving stones onto one another without constantly having to ensure matching spacers.
In the case of a paving stone which is parallelogram-shaped, for example, rectangular, spacers having various designs may be provided on sides joined with one another. As a result, if desired, the joint width of two crossing joints can be designed to vary. As a rule, however, all the joints are provided with the same width.
A square paving stone is preferably designed rotationally symmetrically with respect to a rotation through 90°. Such a stone can be fitted in any orientation into a paving stone bond.
In an advantageous configuration of a paving stone according to the invention, the abutting faces of the spacers are designed such that they permit the fitting of a paving stone into a partially laid paving stone bond by lateral displacement in the horizontal plane of the bond. This is to be considered in particular also when the stone to be fitted already finds neighboring stones which are laid along two crossing lattice lines. A paving stone to be fitted by displacement into such a partially laid paving stone bond consequently fits in simultaneously with two mutually adjacent paving stone walls. Such a configuration of paving stones according to the invention offers enormous advantages, in particular in the machine laying of a paving stone bond, over meshing profiles, in which the stones are to be lowered from above into the partially laid bond.
In a preferred configuration of such a paving stone, each stair-shaped or step-shaped abutting face of the spacer is designed such that it has two regions, which are approximately parallel to-the associated side wall, are stepped from each other, i.e. have different distances from the side wall, and are joined by a joining face which is preferably sloping or, perpendicular to the side wall, planar. In a bond, such paving stones contact one another exclusively at these corresponding abutting faces of their spacers, each spacer extending over the center line of the joint, i.e. the lattice line. The center line in this case divides the region of the preferably sloping joining face of the stepped side walls.
The sloping planar faces are inclined such that they are all together either only rising or only falling with respect to their paving stone side wall when running around the outer contours of the paving stone in a certain rotational direction. As a result, an exemplary configuration of abutting faces is obtained, in which the possibility of fitting into a partially laid paving stone bond, as specified above, is always possible.
For this purpose, however, other shapes are also conceivable. It only has to be ensured that the angle range by which a paving stone side can be fitted onto the side associated with it of the bond of stones by lateral displacement overlaps by the thus-defined push-in angle range of a paving stone side neighboring it, as to be explained in more detail further below with reference to an example.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention is explained in more detail by the description which follows and is represented in the drawing, in which:
FIG. 1 shows a perspective view of a paving stone according to the invention,
FIG. 2 shows a side elevational view of a paving stone according to FIG. 1,
FIG. 3 shows a top plan view of a paving stone according to FIG. 1,
FIG. 4 shows a bottom plan view of a paving stone according to FIG. 1,
FIG. 5 shows a stretching bond of paving stones according to FIG. 1,
FIG. 6 shows a cross bond of paving stones according to FIG. 1,
FIG. 7 shows a partially laid cross bond into which a new stone is just being fitted and
FIG. 8 shows a bond with stone shapes of various sizes.
DETAILED DESCRIPTION OF THE INVENTION
The paving stone 1 according to the invention, as represented in FIGS. 1 to 4, of substantially cuboidal design has a square walk-on face 2 and lateral spacers 3. The lateral spacers 3 have a stepped abutting face 4. The abutting face 4 is composed of two side-parallel regions or step regions 5, 6 and a joining face or sloping face 7, joining these regions. Attached on each side wall 8 to 11 are two spacers 3. They are arranged at a distance d, which in this specific exemplary embodiment is equal on all four side walls 8 to 11. In addition, as shown in FIG. 1, each spacer includes transitional regions and 40, which join step regions 5 and 6 to the associated side wall. Regions 39 and 40 are angled with respect to the associated side wall, and may be perpendicular thereto.
Two mutually complementary spacers 12, 13, to be assigned to each other, of two opposite sides 9, 11 of the paving stone 1 are in each case arranged at the same height h with respect to the length of their side walls 9, 11. The two abutting faces 14, 15 of the complementary spacers 12, 13 to be assigned to each other have an identical profile. In the specific exemplary embodiment shown, the abutting faces 14, 15 are additionally rotationally symmetrical with respect to a rotation through 180°. As a result, the two side walls 9, 11 with the associated spacers 12, 13 and 16, 17, respectively, can be designed symmetrically with respect to a rotation of the paving stone through 180°.
In the present exemplary embodiment, in which the cuboidal basic body of the paving stone 1 has a square and consequently also a parallelogram-shaped or rectangular outline, as evident from the walk-on face 2, all four side walls 8 to 11 are identically designed. The complete paving stone 1 is symmetrical with respect to a rotation through 90°. As a result, each side 9 to 11 of a paving stone 1 can be joined onto any side 9 to 11 of a neighboring paving stone. The paving stone shown in FIG. 1 further includes an upper peripheral edge 41, and a lower peripheral edge 42 disposed at a distance H with respect to upper edge 41, the distance thus corresponding to a height of the paving stone. As shown in FIG. 1, the plurality of spacers are disposed at a distance a from upper edge 41, the distance a preferably being equal to one fifth of H.
If the profile of the outer contours of a paving stone 1 is followed, for example in FIG. 4 with a certain rotational direction, it is established that the non-side parallel, sloping faces 7 are inclined such that they are all together either only rising or only falling with respect to their respectively associated paving stone side wall 8 to 11. With a direction of rotation for example in the clockwise direction in FIG. 4, all the sloping faces 7 are falling with respect to their respectively associated side walls 8 to 11.
In FIGS. 5 to 7, a stretching bond and a cross bond of paving stones 1 according to the invention are respectively represented. The lattice lines R, which in the present cases form a rectangular grid with square lattice elements, are drawn in by dashed lines.
Due to the same configuration of the abutting faces of complementary spacers 12, 13, to be assigned to each other, of two opposite side walls 9, 11, the joining of the paving stones to each other by common interfaces 4 is possible.
Due to the sloping faces 7, in each case two complementary spacers 12, 13, to be assigned to each other, engage, meshing in one another. This meshing provides increased stability of the paving stone bond 19, 21. The individual paving stones are secured better against displacement in the lateral direction.
A special configuration of the abutting faces 4 can additionally achieve the effect that a paving stone 1 can be introduced by lateral displacement (arrow P or arrow Q) into a partially laid paving stone bond 19, 21 and can be joined on simultaneously by two sides. In the present case, this is achieved by the sloping faces 7 of the abutting faces 4 (see FIG. 4) being inclined such that they are either all rising or all falling with respect to their respective side wall 8 to 11 when running around the outer contour in a fixed rotational direction. In the plan view according to FIG. 4, for example, all the sloping faces 7 are falling with respect to their respective side wall 8 to 11, as stated above, when running around the outer contour in the clockwise direction.
In FIG. 6, two individual corner stones 18, 20 are marked by way of example, from the position of which in the paving stone bond 21 it is evident that they can be fitted into the paving stone bond 21 by lateral displacement in arrow direction P and in arrow direction Q, respectively.
The left-hand lower corner stone 18, for example, can be pushed in arrow direction P from below into the structure of the cross bond 21. The lower right-hand corner stone 20, for example, can be fitted in arrow direction Q from the right side. As soon as a stone is surrounded by neighboring stones on more than two sides, it is firmly anchored in its bond. The same considerations also apply, of course, to the stretching bond 19, represented in FIG. 5.
The spacers 12, 13 in the paving stone bond 19 protrude in each case beyond the center line 23 of a joint 22, the center line 23 dividing the non-side-parallel region 7 of each abutting face 4 of these spacers 12, 13. The center line 23 of the joint 22 coincides in the present case with a lattice line R. This does not necessarily have to be the case, but in the present case it is due to the fact that the paving stone side walls 8 to 11 are arranged in straight lines in square forms, all the spacers 3 being designed in the same manner. With side walls 8 to 11 of a curved design, there would, for example, be produced a likewise curved joint 22, the center line of which could, of course, no longer come into alignment with a straight lattice line.
The distance d between two spacers of one side corresponds exactly to half the sum of the side length L and a joint width F of a joint 22 transverse to this side 9, i.e. to the length L R of a lattice element (d=L R /2). As a result, there are two different offsetting possibilities along this side direction. The one corresponds to the stretching bond 19 in FIG. 5, the other to the cross bond 21 in FIG. 6. If there were three spacers attached to the side wall 9, the respective distance d would have to be exactly 1/3 of the length L R of a lattice element, i.e. d=L R /3, consequently it would be possible to realize a total of three offsetting possibilities.
In the partially laid cross bond 21 according to FIG. 7, the arrangement of the paving stones 1 in their bond can be clearly seen on account of the enlarged representation. With the rectangular paving stone 24 there is drawn in by way of example a stone shape which extends over two lattice elements. In an analogous way, paving stone shapes which may also extend over more than two lattice elements are also quite conceivable.
It can be seen from the paving stone 25 to be newly fitted in and also from the two bordering stones 26 and 27 under which preconditions a paving stone 25 to be fitted in can be fitted in by lateral displacement with two mutually adjacent paving stone sides 8, 9 simultaneously into an already cross-laid paving stone bond in its lattice element 28.
With one side, for example the side 8, the paving stone 5 would allow itself to be joined onto the paving stone 26 by a displacement direction at any angle within the angle range α. The angle α arises from the shape of the abutting face of the spacer.
In the present case, it represents the angle which the sloping face 7 assumes with respect to the stepped side-parallel regions 5, 6.
Similarly, it is immediately clear that the paving stone 25 can be fitted with its side 9, for example, against the bordering stone 27 at any push-in angle within the push-in angle range β. The push-in angle range β arises in a manner analogous to the angle range α.
If, then, the stone 25 is to be fitted simultaneously with its side 8 and with its side 9 against the side 29 of the stone 24 and against the side 30 of the paving stone 31, this is possible by lateral displacement precisely when the superposing of the two push-in angle ranges α and β for both sides gives a common angle range γ. Consequently, the paving stone 25 can be fitted into the lattice element 28 by lateral displacement in any direction within the angle range γ.
In FIG. 8, a paving stone bond 32 with a square lattice grid R is represented. In this exemplary embodiment, a plurality of stones of different sizes 33 to 38 are used. The smallest stone 33 in this case occupies precisely one lattice zone, while the largest stone 38 takes up a total of 12 lattice elements. However, all the paving stones 33 to 38 used in this bond 32 occupy an integral number of lattice elements. A paving stone bond 32 in which the smallest stone already occupies a plurality of lattice elements would of course also be conceivable.
Paving stone bonds and paving stone shapes according to the invention whose lattice elements are not square or else not rectangular are of course also conceivable. For example, a hexagonal shape, which produces a honeycomb structure likewise covering a surface area, or the shape of triangles, parallelograms (for example rhomboids), etc. would also be conceivable. | A paving stone configured to be arranged in a paving stone bond in an area-covering grid-shaped lattice of paving stones comprised of lattice elements. The paving stone has side walls and includes a plurality of spacers disposed on the side walls thereof. Each of the spacers has an abutting surface adapted to be positively joined to a respective abutting surface of a spacer on an adjacent paving stone in the lattice of paving stones. In this manner, a crossing joint is formed between the paving stones. The abutting surface of each of the spacers includes a stepped contour for positively meshing with a corresponding stepped contour on the respective abutting surface of the spacer on the adjacent paving stone, the plurality of spacers being disposed on the side walls of the paving stone such that the stepped contours of their respective abutting surfaces are identically oriented in either of two rotational directions defined around the side walls of the paving stone. | 4 |
BACKGROUND OF THE INVENTION
To applicant's knowledge, previous attempts to develop medium to large caliber bulk-loaded liquid propellant guns have been unsuccessful. Nevertheless the advantages of the use of a liquid propellant such as low cost, safety in handling, and ease of maximizing the formula for the particular conditions, etc., have caused ordinance engineers to search for a suitable gun design.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention, unlike previous designs, the pressure build-up in the combustion chamber is controlled by the use of multiple combustion channels contained within the combustion chamber but not in contact with the gun barrel to provide a pressure averaging effect. In this manner, the pressure provided to the combustion chamber is more uniform, i.e., the variances are not so great.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the master chamber and channels;
FIG. 2 is a cross-section of the channels taken across line A--A' in FIG. 1;
FIG. 3 is a side view of the channels with reduced area nozzles; and
FIG. 4 is a side view of tapered channels.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a side view of a liquid propellant gun is shown in which 2 is the master chamber, 4 is the projectile, 6, a channel, and 8, an igniter. Projectile 4 is shown within and surrounded by the gun barrel of the liquid propellant gun. In FIG. 2, a cross-section is shown taken along line 2--2 of the channels.
In FIG. 3, a preferred embodiment is shown in which reduced area nozzles, located in the forward ends of the channels, are used to achieve the forward ejection of the liquid propellant from the channels.
In FIG. 4, a preferred embodiment is shown in which the channels are tapered with large areas aft and smaller areas forward. Both the nozzles and tapered channels can breakup or better disperse the liquid propellant droplets for more efficient distribution.
In operation, the master chamber is filled with liquid propellant which fills the channels as well. One or more igniters is then used to ignite the liquid propellant by in-chamber combustion as shown or by spray-injection combustion. Combustion proceeds in a rearward direction, entering and progressing through the channels, combusting the full charge of liquid propellant.
In-chamber combustion is illustrated in FIGS. 3 and 4. In this configuration, a dual igniter is used, first, to ignite the small volume of liquid propellant contained between the forward facing ends of the channels, and the aft end of the projectile, and, second, to ignite the aft end of the liquid propellant in the channel. This ignition sequence provides the impetus for the projectile to be set in motion by the front combustion process, creating a free-volume into which the propellant in the channels may be injected in reaction to pressurized aft ends. In order to achieve the forward ejection of the liquid propellant from the channels, a reduced-area nozzle (such as shown in FIG. 3) can be used in the forward ends of the channels, or the channels themselves may be tapered with large areas aft and smaller areas forward as shown in FIG. 4. The forced injection through the nozzles serves to break-up the liquid propellant droplets and spray.
A propellant suitable for this invention can be characterized as having about 20% water, 20% organic amine nitrate and 60% inorganic amine nitrate.
The igniters, spray nozzles and tapered channels can be made of conventional metals known to one of ordinary skill in the art. The size and total number of channels will depend on the pressure developed and other variables such as the strength and size of the master chamber. Each of the channels should be sufficiently small so that the total pressure produced is not greater than the master chamber can tolerate. The channels may be rigid if they are a fixed part of the master chamber, or mechanically flexible if they are a portion of the cartridge that contains the liquid propellant.
While the above is illustrative of the Best Mode and preferred embodiments, numerous variations may occur to one of ordinary skill and thus the invention is intended to be limited only by the appended claims. | Improved bulk-loaded liquid propellant guns are provided having a plurality of channels within the master chamber but not in contact with the gun barrel so as to obviate destructive pressure variances. | 5 |
RELATED APPLICATION
[0001] This application claims the benefit of co-pending U.S. provisional application No. 61/765,385 filed Feb. 15, 2013, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention is directed to a system and method for closing a wound.
BACKGROUND OF THE INVENTION
[0003] Traumatic injuries typically occur away from medical facilities. Thus, the victim must be transported from the site where the injury occurred, such as a battlefield or a roadside, to the medical facility for treatment. During this ‘short term’ period, for example, transportation from the site to the facility, it may be best to keep the wound closed, as much as possible, and even covered, if possible, to prevent, for example, ingress of contaminants, or to facilitate treatment.
[0004] Two such devices have been proposed, they are discussed below.
[0005] U.S. Pat. No. 3,971,384 discloses a suture less closure device. The device has a tie strip with an anchor affixed at one end of the strip and a slide lockably engaged on the strip. The anchor is affixed to the skin on one side of the incision and the slide is affixed to the skin on the other side on the other side of the incision. The incision is closed by pulling the strip through the slide and locking the strip in the slide.
[0006] U.S. Design Patent No. D652,145 discloses a wound closure device. The device has two wound closure clips and a strip therebetween.
[0007] While these devices may be used in the situations discussed above, improvements are needed. Those improvements include, but are not limited to, ease of operation, compactness, reduced weight, fewer pieces, rapid deployment, and versatility, to mention a few.
[0008] Accordingly, the invention, discussed below, addresses and improves upon, at least, the issues mentioned above.
SUMMARY OF THE INVENTION
[0009] A system for wound closure has at least two closure elements. One closure element is detachably tethered to another closure element. Each closure element includes: a base member with an integral strap hingably connected to the base member, and a lock member slidably disposed on the strap and being lockable on the strap. Alternatively, the base member defines a plane and the strap being affixed to the base member at an angle to the plane. The system may further include a wound covering disposed between the straps and the wound. The wound covering may be a laminate having at least two layers; a first layer is a moisture impervious layer adapted to contain body heat, and a second hydrophilic layer is adapted to retain moisture.
DESCRIPTION OF THE DRAWINGS
[0010] For the purpose of illustrating the invention, there is shown in the drawings a form that is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
[0011] FIG. 1 is an illustration of one embodiment of the system for closure of a wound.
[0012] FIG. 2 , taken generally along section lines 2 - 2 of FIG. 1 , is an embodiment of the base member.
[0013] FIG. 2A is an enlarged view of a portion of the embodiment shown in FIG. 2 .
[0014] FIG. 3 , taken generally along section lines 2 - 2 of FIG. 1 , is another embodiment of the base member.
[0015] FIG. 4 is an illustration of the inventive system with the strap folded and releasably affixed to the base member and the lock mechanism of the lock member in an open position.
[0016] FIGS. 5A and 5B illustrate one embodiment of the lock mechanism in an open position and a closed position, respectively.
[0017] FIG. 6 is an illustration of the inventive system in operation along with an optional wound covering.
DESCRIPTION OF THE INVENTION
[0018] Referring to the drawings, where like elements have like numerals, there is shown in FIG. 1 an embodiment of the system for closure of a wound 10 , for example, short term closure. Generally, system 10 comprises a closure element 12 . In one embodiment, several closures elements 12 may be joined together via a tether 14 . But, closure elements 12 may be independent, i.e., not tethered. Several, as used herein, may mean at least two, but may include up to 12 , or any whole number between 2 and 12 .
[0019] The tether 14 may be breakable or cuttable, so that the number of closures 12 may be tailored to a suitable number for closure of the wound. Tether 14 may be positioned on an upper portion of the closure elements 12 , so that the tether 14 does not touch the skin.
[0020] The system 10 may be made of one or more injection moldable thermoplastic materials, alone or in combination. Such thermoplastic materials include, but are not limited to, polyolefins (for example, polyethylene and polypropylene), polyesters (for example, polyethylene terephthalate), polyamides (for example, nylon), or the like.
[0021] Closure element 12 generally includes a base member 16 , a strap 18 , and a lock member 20 . The base member 16 may be integral with the strap 18 . The lock member 20 may be slidably and/or removably engaged with strap 18 .
[0022] Referring to FIGS. 1-4 , the base member 16 will be discussed in greater detail hereinafter. Base member 16 generally includes a strap fastener 22 and a bottom plate 24 . Base member 16 optionally includes at least one pair of staple holes 26 through the bottom plate 24 . Any number of pairs of staple holes may be used, for example, 1-4 pairs of staple holes including any whole number between 1 and 4. The staple holes 26 may be used so that the base member may be stapled to the skin surrounding the wound. The base member may also optionally include at least one pair of staple guides (e.g., teeth) 28 , for example, upstanding from the lateral edges of the bottom plate 24 . Additionally, the staple guides 28 allow the base member 16 to be more flexible therebetween. Any number of pairs of staple guides may be used, for example, 1-6 pairs of staple guides including any whole number between 1 and 6.
[0023] As shown in FIG. 4 , strap fastener 22 may be used to releasably secure strap 18 , so that the strap 18 may be held away for the wound. Strap fastener 22 may be any mechanism that can releasably hold strap 18 . The strap fastener 22 may be generally located on the base member 16 at an end of the bottom plate 24 distal the strap 18 . In one embodiment, shown in FIGS. 1 , 2 , and 4 , strap fastener 22 may comprise a pair of lateral clips 30 , each clip 30 spaced from the other so as to releasably secure strap 18 therebetween. The strap fastener 22 may optionally include strap engagement member 31 . Strap engagement member 31 working with clips 30 may more securely hold the folded strap 18 in strap fastener 22 . In another embodiment (not shown), strap fastener may be a post with mushroom head upstanding from bottom plate 24 for releasable engagement with one or more holes (not shown) through the strap 18 .
[0024] Referring to FIG. 2A , base member 16 may include an adhesive 32 for releasably securing base member 16 to the skin adjacent the wound. In one embodiment, the adhesive 32 may be affixed to a bottom surface of the bottom plate 24 . Adhesive 32 may be any adhesive suitable for releasably adhering the base member 16 to the skin adjacent the wound. The adhesive 32 may be a hydrocolloid dressing (for example, commercially available under such tradenames as Duoderm, Granuflex, Ultec, and 3M Tegaderm Hydrocolloid) and/or pressure sensitive adhesive. In one embodiment, the adhesive 32 covers all or a portion of the bottom surface of bottom plate 24 . In one embodiment, the adhesive 32 may be protected, prior to use, by a release layer 34 . In another embodiment, adhesive 32 may include a mesh (not shown) throughout the adhesive 32 and may extend beyond the peripheral edge of the adhesive 32 .
[0025] The base member 16 may be integral with strap 18 . Integral, as used herein, may refer to the base member 16 and the strap 18 being molded as a single unit. The joint between the base member 16 and strap 18 should be flexible (i.e., capable of bending to allow fastening of the free end of the strap 18 to the base member 16 as shown in FIG. 4 ). The strap 18 may be hingably connected with the base member 16 . In one embodiment, see FIG. 2 , a hinge 36 joins the base member 16 with strap 18 . Hinge 36 , as shown in FIG. 2 , may be formed by a thinning of material between the base member 16 and strap 18 (e.g., a living hinge). In another embodiment, see FIG. 3 , the strap 18 is joined to the base member 16 at an angle 38 . Angle 38 may be any angle greater than 0° and less than 90°. The angle 38 may be in the range of 10°-45°, or 15°-35°. In one embodiment, the angle 38 may be about 30°.
[0026] Strap 18 , see FIGS. 1 , 4 , 5 A, and 5 B, is a elongated member extending away from the base member 16 . The strap 18 is flexible. The strap may have a plurality of teeth 40 along a surface of strap 18 (for example, the upper surface). These teeth 40 , in one aspect of the invention, may work with strap engagement member 31 of the strap fastener 22 (discussed above); and in another aspect of the invention, these teeth 40 may engage with strap engagement member 54 to hold the strap 18 fast in locking mechanism 42 (discussed below). The strap 18 may be any length. In one embodiment, the length may range from 12 inches to 36 inches. Strap 18 may be severable. For example, the strap may be severed (for example, with a knife or scissors) along its length so that the strap length may be tailored to a suitable length for closure of the wound. In one embodiment (not shown), the strap 18 may include one or more notches at regular intervals (for example, 1 or 2 inches) along the length of the strap 18 to facilitate severability. The notch may run across the width of the strap 18 (i.e., generally perpendicular to the longitudinal axis of the strap 18 ) and may be an area of the strap that may be generally thinner in depth than other areas of the strap, so that the notch acts as a guide for a knife to facilitate strap cutting in the dark as may be necessary under battle field conditions.
[0027] Lock member 20 , see FIGS. 5A and 5B , may be slidably releasable on strap 18 . Lock member 18 may be slid along strap 18 to facilitate closure and access to the wound. Lock member generally includes a locking mechanism 42 for releasably engaging strap 18 . In one embodiment, the lock member 20 may include a bottom plate 44 with the locking mechanism 42 joined to an upper surface of the bottom plate 44 .
[0028] Lock member 20 optionally includes at least one pair of staple holes 26 through the bottom plate 44 . Any number of pairs of staple holes may be used, for example, 1-4 pairs of staple holes including any whole number between 1 and 4. The staple holes 26 may be used so that the base member may be stapled to the skin surrounding the wound. The base member may also optionally include at least one pair of staple guides (e.g., teeth) 28 , for example, upstanding from the lateral edges of the bottom plate 44 . Additionally, the staple guides 28 allow the lock member 20 to be more flexible therebetween. Any number of pairs of staple guides may be used, for example, 1-6 pairs of staple guides including any whole number between 1 and 6.
[0029] The locking mechanism 42 , in one embodiment, may include a foldable lid 46 mounted via a hinge 48 to wall 50 . The lid 46 is movable from an open position, FIG. 5 A, to a closed position, FIG. 5B . The lid 46 may include a clasp 52 which is releasably engagable with wall 50 . Optionally, the lid 46 may include strap engagement member 54 for holding the strap in a non-slidable manner when the lid 46 is in the closed position. Optionally, the locking mechanism 42 may include a mechanism (not shown) so that when lid 46 is in the closed position, the strap 18 may be pulled therethrough, thereby closing the wound by drawing the base member 16 and lock member 20 together. This mechanism may only allow the strap to be pulled through in one direction and hold fast in the opposite direction.
[0030] Lock member 20 may include an adhesive for releasably securing lock member 20 to the skin adjacent the wound. In one embodiment, the adhesive may be affixed to a bottom surface of the bottom plate 44 . The adhesive may be any adhesive suitable for releasably adhering the lock member 20 to the skin adjacent the wound. The adhesive may be a hydrocolloid dressing (for example, commercially available under such tradenames as Duoderm, Granuflex, Ultec, and 3M Tegaderm Hydrocolloid) and/or pressure sensitive adhesive. In one embodiment, the adhesive covers all or a portion of the bottom surface of bottom plate 44 . In one embodiment, the adhesive may be protected, prior to use, by a release layer. In another embodiment, adhesive may include a mesh (not shown) throughout the adhesive and may extend beyond the peripheral edge of the adhesive. The adhesive may be positioned on the lock member 20 in the same fashion as the adhesive 32 is employed with the base member 16 , and shown in FIG. 2A .
[0031] In operation, referring to FIG. 6 , system 10 is removed from a sterile packaging (not shown). The system 10 is spread, as necessary, so that the base member 16 is on one side of the wound, the lock member 20 is on another side of the wound, and the strap 18 traverses the wound. With the locking mechanism 42 in the open position ( FIG. 5A ), the base member 16 and lock member 20 are affixed to the skin adjacent the wound, via the adhesive. Staples (not shown) may be used to further secure the base member 16 and lock member 20 to the skin adjacent the wound. Strap 18 is inserted into the open locking mechanism 42 . The base member 16 and lock member 20 may be drawn together, whereby the wound may be closed (closure may only be sufficient to prevent internal organs from spilling from the wound during transportation, full closure of the wound may not be necessary or possible). Thereafter, the lock mechanism 42 may be closed ( FIG. 5B ), so that the strap 18 is fixed in place. Excess strap 18 (e.g., strap 18 extending beyond lock member 20 ) may be trimmed, as desired. If necessary to gain access to the wound after closure with system 10 , the locking mechanism 42 may be released ( FIG. 5A ) for access and then reclosed ( FIG. 5B ).
[0032] Optionally, wound covering 60 may be included with system 10 . Wound covering 60 adds, among other things, further protection to the wound. Wound covering 60 may also, without limitation, prevent ingress of contaminants into the wound, prevent spillage of internal organs from the wound, assist in retaining body heat, assist in retaining moisture that may escape from the wound, and provide a vehicle through which medicines and/or fluids may be administered to, or through, the wound. Wound covering 60 may be any size. For example, the wound covering 60 may have dimension of 12 inches by 12 inches by 3 mm.
[0033] Wound covering 60 , in one embodiment, may be a laminate. The laminate may have at least two layers. A top layer 62 may be for preventing escape of heat and moisture through the wound and preventing ingress of contaminants to the wound. Top layer 60 , in one embodiment, may be an aluminized plastic sheet. The aluminized surface faces toward or away from the wound. A middle layer 64 may be for administering fluids and/or medicines to the wound. Middle layer 64 may be a hydrophilic foam and/or an opened cell foam. Middle layer 64 may be affixed to top layer 62 . Additionally, wound covering 60 may include a third layer. Bottom layer 66 may be a perforated plastic film, so that fluids and/or medicines fed into the middle layer 64 may be distributed into the wound. Top layer 62 may be joined to bottom layer 66 via a weld seam 68 . Weld seam may be made by any suitable technique (for example, thermal weld, ultrasonic weld, adhesive, radio-frequency weld, and the like). Wound covering 60 may further include a fluid ingress port 70 . Port 70 may be coupled with, for example, a saline bag (not shown). Port 70 is in fluid communication with middle layer 64 and extends beyond the weld line 68 . Fluids and/or medicines may be administered from the saline bag through the port 70 to middle layer 64 , and then into the wound from the middle layer 64 and through the bottom layer 66 . Port 70 may be a luer lock-type device. Wound covering 60 may be supplied with system 10 folded and packaged in a sterile packaging or can be opened and worn on the inside of a battlefield helmet.
[0034] In operation, the wound covering 60 is spread over the wound, and then system 10 may be deployed as described above.
[0035] The system 10 may be compressed into a relatively small sterile package and is light-weight. Thus, it may be easily carried into a battlefield situation.
[0036] While, originally intended for short term closure, the system 10 may also have benefit in other surgical-type procedures, including, for example, any hospital/medical environment, such as an operating theater, emergency room, trauma center, or the like.
[0037] The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | A system for wound closure has at least two closure elements. One closure element is detachably tethered to another closure element. Each closure element includes: a base member with an integral strap hingably connected to the base member, and a lock member slidably disposed on the strap and being lockable on the strap. Alternatively, the base member defines a plane and the strap being affixed to the base member at an angle to the plane. The system may further include a wound covering disposed between the straps and the wound. The wound covering may be a laminate having at least two layers; a first layer is a moisture impervious layer adapted to contain body heat, and a second hydrophilic layer is adapted to retain moisture. | 0 |
"This is a division of application Ser. No. 07/329,170 filed on Mar. 27, 1989 now U.S. Pat. No. 4,901,414."
FIELD OF THE INVENTION
This invention relates to a method and apparatus for assembling heat exchanger elements and particularly to such a method and apparatus to automatically receive and couple such elements when inserted.
BACKGROUND OF THE INVENTION
Heat exchangers of the plate type are comprised of pairs of preformed plates joined to other pairs at their ends by integral bosses and separated at their middle section by air centers or corrugated fins, the plates and fins all being brazed together so that each pair of plates becomes a tube for carrying refrigerant, the bosses serving as a manifold for permitting refrigerant flow from one tube to another, and the fins facilitating heat exchange between the tubes and air flowing outside the tubes. U.S. Pat. No. 4,470,455 issued to Sacca describes such a plate type heat exchanger in detail.
The assembly of the plate type heat exchanger elements into a core ready for brazing has typically been carried out largely by hand operations. Specifically, the first step is to assemble a fin element between two plates and crimp the plates together into subassemblies where their bosses connect, and then manually stack such subassemblies along with side plates into a fixture which holds each subassembly in place.
It is desirable to enhance the assembly practice by an improved method and machine for assembly. In particular it has been found that the process is improved in terms of automation and in terms of reducing spacing in the fixture if it is begun by joining the plates together into pairs that eventually become tubes and inserting the plate pairs and side plates into a fixture and then inserting the centers between the plates. It is desirable to have a machine to perform the assembly operations to reduce the manufacturing expense and otherwise improve the efficiency of the assembly practice. It has been demonstrated that the machine assembly of plate pairs, air centers and side plates into a pallet is practical.
It is known to automatically assemble other styles of heat exchanger cores as shown in the U.S. Pat. No. 4,321,739 to Martin et al. In Martin et al the tubes are first inserted into blocks carried by chains and the centers are then loaded between the tubes which are well spaced by the blocks. The tubes and centers are gathered together as the blocks are removed from one tube at a time. Thus tubes and centers are arranged in alternate rows and headers are joined to the ends of the tubes and tanks are joined to the headers to couple the tubes together. The tubes do not directly coact and they have exteriors which facilitate the insertion of centers, as contrasted with the plate and center type which requires that the plates each mate with their neighbors as well as to sandwich the air centers. Further, the plate edges protrude in a way to interfere with center insertion so that large spacings between the plates would be required to permit center insertion. The large spacings necessitate a large gathering distance and also allow centers to get out of position so that centers can interfere with the coupling of the plates during the gathering process.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a practical method and apparatus especially adapted to the automatic assembly of plates and centers into a heat exchanger core.
The invention is carried out in an apparatus for assembling pairs of plates and air centers for a heat exchanger core by a pallet system comprising; a frame movable in a longitudinal direction, a plurality of blocks in the frame supported along each side of the frame and mounted for limited movement in the frame in the longitudinal direction, each block having a slot for receiving an end of a pair of plates and positioned opposite a similar block for receiving an opposite end of the pair of plates, and means for selectively engaging the blocks for moving the blocks and the frame longitudinally, the engaging means being effective to position the blocks at a loading station and to vary the spacing of the blocks to facilitate insertion of elements into the frame.
The invention is further carried out in a process for assembling pairs of plates and air centers for a heat exchanger core in a pallet having plate holders by the method of inserting plates into holders comprising the steps of: positioning a holder at a loading station in a position spaced from adjacent holders so that adjacent parts do not interfere with plate insertion, dropping a pair of plates into the holder, then moving the holder toward an adjacent holder to mate one pair of the plates with a previously loaded pair of plates, and repeating the positioning, dropping and moving steps for the next adjacent holder until the holders are filled as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other advantages of the invention will become more apparent from the following description taken in conjunction with the accompanying drawings wherein like references refer to like parts and wherein:
FIG. 1 is an elevation partly in section of stacked plates for a heat exchanger core assembled by the method and apparatus of the invention,
FIG. 2 is an isometric view of an indexed pallet system according to the invention,
FIG. 3 is a plan view of the right half of a pallet and associated screw assembly of FIG. 2,
FIG. 4 is a side view of the pallet of FIG. 3,
FIG. 5 is an end view of the pallet of FIG. 3 with a plate of FIG. 1 loaded into the pallet and with an end plate removed to show block detail,
FIG. 6 is a partly broken away end view of the block of FIG. 5, and
FIG. 7 is a partial plan view of the dual screw arrangement of FIG. 2 and associated pallets.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A portion of the heat exchanger core to be assembled by the apparatus and method of the invention is shown in FIG. 1. Plate pairs 10 which will form tubes when brazed consist of plates 12 and 14 which when stacked form a heat exchanger core adapted to be used as an evaporator. The plate pairs 10 are stacked to define a space 16 therebetween for the flow of air. The space 16 includes a corrugated metal center or fin 17 with louvers struck out therefrom for increasing the heat exchange efficiency. Only a portion of the center 17 is illustrated.
For standard plate pairs 10 the individual plates 12 and 14 are configured identically, one of the plates is simply inverted and rotated 180° relative to the other. Each plate has a flat peripheral edge portion 18 and the portions 18 of the two plates are formed so as to engage one another prior to braze jointure. Thus each pair of plates, when brazed, forms a tube for refrigerant. Inlet and outlet manifolds 24, 26 are formed by outwardly offset and generally circular portions 28 in each end of plates 12 and 14. An opening 30 is provided in the top surface at one end and an opening 32 is provided with an outwardly raised flange portion 34 at the other end. Thus, the plates are designed so that, when stacked, the flange portion 34 surrounding opening 32 fittingly engages the opening 30. This provides a registering relationship between the plates of two adjacent tubes.
In some cases the plates 12 and 14 are not configured identically in the sense that an opening 30 may be omitted to structure the manifold for fluid flow management through the core. The plate on either end of the core will be equipped with an inlet or outlet fitting at the opening 30 or 32. Thus the core is made up primarily of "standard" plate pairs combined with a few "special" plate pairs. In any event they all couple together in the same manner. The plate and heat exchanger structures are more fully described in the U.S. Pat. No. 4,470,455 to Sacca.
The general organization of the assembly machine is shown in FIG. 2. A pallet 40 comprises an open-sided frame 42 with vertical end plates 44 at each corner of a horizontal base plate 45. Four rods 46 supported by the end plates 44 extend longitudinally along each side to pass through and hold a plurality of perforated blocks 48 which can slide a limited amount along the rods. A coil spring 49 under compression surrounds alternate rods 46 on each side between an end plate 44 and the nearest block 48 to hold the blocks together against the other end of the frame unless the spring force is overcome. The blocks 48 each have a slot 50 for receiving the edges of a plate pair 10 adjacent an offset portion 28. Each block also has an outboard cam follower 52 extending to the side of the pallet. A lead screw 54 with its axis parallel to the rods 46 at each side of the path of the pallet engages just a few of the cam followers 52 at a given time. The lead screws 54 are synchronously rotated by servomotors 56 to advance the corresponding blocks 48 longitudinally so as to precisely position the blocks and to advance the entire pallet 40 as well. A microprocessor based controller 57 controls the servomotors. The lead screws are positioned at a loading station for plate pairs 10 and the pallets 40 are carried to the loading station by a power and free conveyor 58 which depends on a frictional contact to drive the pallet. The lead screws engage the cam followers of the blocks and positively and precisely position the blocks at a feed plane where plate pairs are dropped into the slots 50 in the blocks 48. As shown in FIG. 2 the first few blocks are holding plate pairs 10 and subsequent blocks are prepared to receive a plate pair being inserted as indicated by an arrow 60.
The width of the blocks is such that when they are nested together the adjacent plate pairs 10 are stacked together as shown in FIG. 1. A critical function of the pallet system is that the pitch of the lead screw 54 is greater than the width of the blocks so that the few blocks that are actively engaged by the lead screws are spaced far enough to permit insertion of the plate pairs 10 without interference by an adjacent plate pair and the adjacent pairs are moved into a nested assembly as they are released by the lead screws. The plate pairs 10 may not necessarily be loaded at the same station since it may be more convenient to have separate loading stations for each type of plate pair, standard or special. The conveyor 58 carries the pallet from one station to the next. At each station the blocks 48 are spaced apart as they pass the feeding plane and the proper plate pairs are inserted into empty slots according to a preset program. Centers 17 are also supplied to the pallet in the same manner. Center insertion occurs after all the plates are inserted since the plate pairs 10 position and laterally support the centers.
A center loading station is shown in FIG. 2 downstream from the plate loading station. Lead screws 62 driven by servomotors 64 are on opposite sides of the conveyor 58. The optimum spacing of the blocks for center insertion is less than for the plate pair insertion. Thus the lead screws 62 at the center loading station have a smaller pitch than those at the plate pair loading station. Accordingly, the pallet 40 can provide various insertion spacings under control of the lead screws at a various stations.
A special feature at the center loading station is an auxiliary lead screw 66 drivingly coupled to each lead screw 62 by a shaft 68 but spaced from the lead screw 62 by a distance of perhaps one half the length of a pallet 40. The purpose of the lead auxiliary screw 66 is to engage a pallet 40' which is waiting to enter the center loading station and positively advance the pallet at a rate determined by the motor 64 speed. In the absence of the lead screw 66 the pallet would be advanced by the power and free conveyor 58 which relies on friction to move the pallet and is accordingly limited in its ability to accelerate the pallet. The positive advancement is most advantageous when the waiting pallet is touching or nearly touching the pallet in the station. By positively advancing the waiting pallet 40' it can be accelerated quickly for positioning in the station under control of the lead screw 62, thus minimizing the time lapse between the last center insertion in one pallet 40 and the first center insertion in the next pallet. The benefit of minimizing the time lapse is to allow the supply of centers to proceed at a more uniform rate. In the most efficient arrangement the centers are fed to the pallet directly from the machine making the centers. That machine operates best at a constant output rate but it can vary its rate somewhat to accommodate the time lapse between pallets, providing that the time lapse is small. In other words, it is not desirable to stop the supply of centers each time a pallet is positioned in the loading station but some slow down is permissible. The positive advancement of the waiting pallet by the lead screw 66 in conjunction with the control by lead screw 62 permits its precise positioning in the loading station in the minimum time.
Details of the assembly machine are better shown in FIGS. 3, 4, 5 and 6 and include some elements not shown in FIG. 2. The base plate 45 has a large central aperture 70 and a short pedestal 72 at each end between the end plates 44. A platen 74 (FIG. 5) is supported on the pedestals with its upper surface flush with the bottom edges of the elements to be loaded into the pallet and is the support for centers when they are first loaded and are not yet held by the adjacent plates. The platen 74 also is used to lift the assembled core out of the pallet via an elevator, not shown, which pushes up through the large aperture 70 in the base plate.
The slot 50 in each block is configured to the shape of the plates 10 so that the plate pairs nest in the slot. The blocks also have relief to accommodate the offset portions 28 of the plates. Each block 48 has, in addition to the slot 50 and the cam follower 52, two flat side faces 75 which abut similar faces in adjacent blocks, two large holes 76 and two small holes 77 receiving the rods 46. The four holes are positioned at corners of a rectangle and two diagonal small holes 77 are surrounded by a boss 78 protruding beyond the faces 75 on one side of the block and containing a bushing 80 for sliding on the rods 46. The other set of diagonal holes 76 are large enough to receive the bosses 78 of the adjacent block. For the blocks to fit together with the adjoining faces 75 in contact two block types (for each side of the pallet) are used alternately so that each boss 78 of one block will align with and fit in the corresponding large hole 76 of the adjacent block. One type of block rides on two of the rails and the other type rides on the other two rails. The bosses protrude toward the end of the pallet 40 that contains some free space for block movement. The springs 49 on two of the rods reside in the space and extend between the end plates 44 and the bosses 78 of the end block to press the blocks together in the absence of the lead screws. When the lead screws engage some of the blocks the springs 49 are compressed due to the separation of those blocks. The frame 42 is moved by the lead screws 54 via forces acting through the blocks and the springs 49 if the springs are in the leading edge of the pallet. The other end of the pallet may be positioned in the front in which case the force from the lead screws is delivered directly by the blocks to the frame 42.
The lead screws 54 comprise helical threads 82 having a pitch determined by the block thickness and the block separation appropriate for a particular loading station. The thickness of each thread is sufficient to span the distance between adjacent cam followers 52. This assures that each block will be positively positioned by the screw threads. The cam followers 52 are essentially elliptical to accommodate the pitch angle of the threads.
FIG. 7 shows the lead screw 62 connected to the auxiliary lead screw 66 and coupled respectively to a pallet 40 in the center loading station and a waiting pallet 40'. The screw driving shaft 66 is supported in three spaced bearing blocks 84 and is driven at one end by a motor (not shown). Each screw 62, 68 is mounted on the shaft 66 and keyed thereto by a pin 86 passing through a hub 88 on the screw and through the shaft. The screw 62 is the same as the screw 56 at the plate loading station except for a smaller lead and thread width to conform to the smaller block spacing required for the center insertion. The pallets 40, 40' are shown with one closely following the other. A bumper 90 is fixed to the trailing end of each pallet for desired spacing of the waiting pallet from the one being loaded. This allows the leading blocks of the waiting pallet to smoothly mesh with the screw 68. In operation, the waiting pallet 40' is brought into contact with the rear end of the pallet 40 by the conveyor 58 preferably before the pallet 40 enters the loading station. When the first blocks of the pallet 40' reach the screw 68 the blocks will be captured by the screw so that the pallets 40 and 40' will be advanced together by the screws 62 and 68. When the pallet 40 is fully loaded with centers the motors 64 will accelerate to quickly remove the pallet 40 and simultaneously move the waiting pallet 40' into the station with accurate positioning for the insertion of the next center dropped into the loading plane.
Accurate positioning of the blocks is assured by driving the blocks directly by the lead screws and by driving the lead screws by servomotors under computer control. The amount of rotation of the servomotors and thus the position of each block is precisely controlled by the computer program. | An apparatus for assembling heat exchanger elements includes a pallet comprising a frame and a plurality of blocks slidably aligned on each side of the frame with opposed pairs of blocks slotted to receive pairs of plates dropped into the pallet. Lead screws driven by servomotors and engaging the blocks position the blocks at the loading station and control the block spacing (determined at each station by the screw pitch) to allow plate insertion or to allow insertion of fin elements between the plates. To quickly move the pallet into the station auxiliary lead screws connected to the main screws engage the blocks of the pallet outside the loading station to assert positive controlled advancement force on the pallet. | 8 |
FIELD OF THE INVENTION
The present invention relates to a power line communication (PLC) system, wherein information is transmitted along a power conductor. The invention is particularly suitable for oil wells and general purpose waterlift pumps, where a load such as an electric submersible pump (ESP) is installed deep in an oil well, bore hole or caisson and where the remoteness of the load results in a technical and commercial obstacle to installing a separate communication cable.
BACKGROUND OF THE INVENTION
Within power line communication systems there is provided a 3 phase power supply to power a load. If this supply were to power a perfectly balanced load the voltage between the neutral point of the supply and the neutral point of the load would be 0 volts. Subsequently, if both the supply neutral and the load neutral were connected using a neutral wire or both were connected to earth, then the current flow in this neutral or earth link would be 0 amps.
However, electrical systems are not perfectly balanced and for a motor powered over a long cable with various junction boxes and connectors, each phases impedance will be affected by a multitude of factors, such as: the length of the cable, the connection resistance, the position of the winding in the slot, the differences in winding lengths, the construction of the motor, the construction of the cable and the transposition of the cable. Such imbalances in a load create a voltage difference between the two neutral points and as current flow between the two neutrals is undesirable as it will cause a loss of power and they are not typically connected.
Power line communication systems are well known in the art. One such known system provides a means of communicating data from a remote inductive electrical load, such as a motor by modulating the motor current. However this type of system may require the need for modifying the motor windings.
Other existing PLC methods which use earth link currents, use a DC coupled current to act as the communication carrier. This however requires a large coupling package at both the supply and the load neutral connection, which are designed to remove signals above a few Hertz to remove the known imbalance voltage differences and as such limits the data transfer rate to a few bits per second. Furthermore, these types of coupled signals also suffer from the fact that they transfer less power to the transmitter.
It is an object of at least one aspect of the present invention to obviate or mitigate one or more of the aforementioned problems and disadvantages.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a method of communicating information along a power conductor between a power supply and a load supplied by said power supply, said method comprising the steps of causing a flow of current from the power supply between two different locations within the power system through a reference conductor not required for normal operation of the power system, and modulating the flow transmitted through the reference conductor by varying an impedance placed in the path of said current flow to provide at least two current states which are used to transmit information along the power system.
Preferably the method uses earth as the reference conductor.
According to a second aspect of the present invention there is provided a power line communication system for use with a 3 phase power supply system said power line communication system comprising:
a 3 phase power supply,
a 3 phase load, incorporating a 3 phase power conductor to connect the 3 phase actual load to the 3 phase power supply,
a transmitter impedance means coupled between said load and a voltage reference conductor, said transmitter impedance being variable between at least a first impedance value and a second impedance value to generate a respective first and second current value, said first and second current values being used to transmit information along said reference conductor,
a receiver impedance means coupled between said power supply and said voltage reference conductor, said receiver impedance completing the transmission circuit and permitting the measurement of the current state.
Preferably, said 3 phase supply has a neutral connection and said 3 phase load has a neutral connection, and at least one transmitter is coupled at one of said neutral connections and at least one receiver is coupled to the other of said neutral connections, said at least one transmitter and said at least one receiver being powered by a normally occurring voltage differential between the supply neutral connection and the load neutral connection for providing communication signals.
Preferably the first and second current values differ in amplitude only.
Alternatively any standard modulation technique including amplitude modulation, frequency modulation or phase modulation may be implemented to achieve the variation of current flow through the reference conductor.
Preferably the reference conductor is earth.
Conveniently the reference conductor may be a conductor insulated from earth.
Preferably the receiver impedance is connected between a neutral connection of the power supply and the reference conductor.
Alternatively the receiver impedance may be connected between any point of the power supply and the reference conductor.
Preferably the transmitter impedance is connected between a load neutral point, such as a star connection of a three phase motor and the reference conductor.
Alternatively the transmitter impedance may be connected between any point of the load and the reference conductor.
Most preferably there is provided a line powered transceiver at the load end and the supply end of the power system, both of which conveniently incorporate a fixed and variable impedance enabling duplex communication.
Preferably one transceiver transmits during one half cycle of a reference conductor current flow and the other transceiver on the other half cycle to achieve duplex communications.
Conveniently, there is provided a sensing device that enables information to be received from another transceiver by measurement of reference conductor current.
Advantageously an offline voltage source is provided in conjunction with one transceiver, enabling communication to be maintained when the power supply is not powered.
Conveniently, there is also provided a switched diode at the load transceiver, permitting insulation testing of the load and the apparatus connected at the load end of the power system.
Preferably the transceivers are powered by the normally occurring voltage differential between the supply neutral connection and the load neutral connection.
Advantageously there is provided means or a method to create a sufficient voltage differential to power the line transceivers and thereby allow communications between them.
Conveniently, the voltage differential between the supply neutral connection and load neutral connection may be created by use of a variable impedance placed in at least one conductor of the power line. Wherein the variable impedance is used to create an imbalance in the load, said impedance providing a means for controlling the potential difference exhibited between the supply neutral and load neutral.
Advantageously there is provided a control system that allows the impedance to be varied either manually, or by means of an automatic feedback system, in order to be able obtain the desired voltage differential exhibited between the supply neutral and load neutral.
Alternatively, the transceivers are powered by a voltage differential is created across the communication system by connecting the supply transceiver to one of the supply phases of the power source whilst the load transceiver is connected to the load neutral connection.
Alternatively, the transceivers are powered by a voltage differential is created across the communication system by connecting the load transceiver to one of the phases of the load whilst the supply transceiver is connected to the supply neutral connection.
Conveniently, the transceivers may be powered by a voltage differential is created across the communication system by connecting the supply transceiver to one of the supply phases of the power source and by connecting the load transceiver to a different phase at the load end.
Alternatively, the transceivers are powered by a phase conductor voltage drop, which is achieved by connecting the transceivers at either end of a conductor of the power line.
Advantageously the transceivers are powered by the voltage differential between any two points in the power system.
Advantageously the load insulation impedance may be determined by measurement of the reference conductor current flow.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the present invention will now be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a three phase power system with a fixed supply neutral-earth impedance and a variable motor neutral-earth impedance;
FIG. 2 is a duplex transmission system using a modulated neutral current driven by a differential voltage between the supply and motor neutral points;
FIG. 3 is an electrical diagram of an individual inductor switch shown in FIG. 2 ;
FIG. 4 is an electrical block diagram of the system shown in FIG. 2 ;
FIG. 5 is an amplitude modulated current waveform showing duplex digital communications at 2 bits per Hertz;
FIG. 6 is an electrical diagram showing a communications system in accordance with a second embodiment of the invention with a differential voltage controlled by variable line impedance.
FIG. 7 is an electrical diagram of a communication system in accordance with a third embodiment of the invention showing a phase voltage used for the communications differential created by connecting the supply transceiver to one phase.
FIG. 8 is an electrical diagram of a communication system in accordance with a fourth embodiment of the invention showing a cable voltage drop used for the communications differential, created by connecting transceivers at either end of the cable.
FIG. 9 is an electrical diagram of a communication system in accordance with a fifth embodiment of the invention showing both the supply and load being delta connected, in which a phase voltage differential is used for the communications differential, created by connecting one transceiver to a supply phase and the second transceiver to a different phase at the load.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there is shown a three phase, power source 1 supplying a remote motor 6 through a substantial length of power cable 5 . The power source 1 having a neutral point 2 which is connected to an earth point 4 through a fixed value inductance 3 . Whilst the motor 6 is connected in a star configuration creating a motor neutral point 7 which is connected to earth via a fixed inductance 8 and a variable inductance 9 .
The voltage seen at the neutral point of the power supply 2 and the neutral point of the motor 7 are not equal. This is due to resistances in each conductor of the power cable 5 , and the general construction details of the motor 6 , which means the load is not perfectly balanced and hence will result in a voltage differential between the supply neutral connection and the load neutral connection. This resultant voltage is applied across the three inductors 3 , 8 , 9 via earth which results in a current flow through the inductors via earth, where Ohm's law dictates the value of current
current=voltage/impedance
where
impedance=fixed impedance+variable impedance.
Therefore, by variation of the variable impedance 9 it is possible to vary the current through the circuit.
Switching a short circuit across the variable impedance 9 results in the variable impedance 9 changing between a short circuit and a fixed impedance. This results in the current changing between one of two states. These two states being used to send a single bit of information.
The resultant current measured through the fixed inductance 3 varies depending on the total circuit loop impedance. By measuring this current, the current can be categorised as either being low or high, indicating a low short circuited impedance or high impedance. The value of the current high or low being the state of a single bit of transmitted information.
Referring to FIG. 2 there is shown a diagram for a duplex, digital communications system having a data transfer rate of 200 bits per second, for a power frequency of 50 Hertz, the bandwidth being split into 100 bits per channel. The three phase power supply 1 is connected to a star connected motor load 6 over a substantial length of power cable 5 , with a transceiver connected between the power supply neutral 2 and earth 4 , and another transceiver connected between the motor star point 7 and earth 4 . The transceiver connected at the power supply end also has an offline power supply 27 attached to it, whilst the transceiver connected at the motor end has a switched diode 11 connected in series between the motor neutral 7 and the transceiver.
The offline power supply 27 provides power to the communications system, that is both transceivers when the motor is not supplied with power from the power source 1 . When the motor is powered, relay 26 is closed and relay 25 is open, thereby disconnecting the offline power supply 27 . However, when the motor is off, the relays 25 and 26 are in the opposite state thereby connecting the offline power supply 27 .
The switched diode 11 permits insulation testing of the power supply 1 , the cable 5 and the motor 6 by presenting a diode barrier 12 to the circuit when the relay 13 is opened. However the relay 13 is closed whenever the transceiver 14 is powered. When the power supply 1 is switched on the relay 13 is open and the diode 12 does not permit ac power to flow. However, the rectified current flowing through the inductor switches 10 generates power in the inductor switch power supply 34 which supplies power to the relay 13 via a dc-dc isolator 35 and common power supply 16 . An alternative means of controlling the relay is to power the relay 13 directly from a secondary winding on the fixed inductor 8 .
FIG. 3 shows the construction of the inductor switch 10 shown in FIG. 2 . Across the main power terminals 29 and 30 is a fixed inductor 32 . In parallel with this fixed inductor 32 is a diode 31 and transistor 33 which are in series with each other, this circuitry allows the current to bypass the fixed inductor 32 whenever the transistor 33 is turned on. The transistor 33 is switched on using an external signal 37 from a micro-controller 19 and the external signal 37 is connected to the transistor 33 via an opto-isolator 38 . A power supply 34 generates the power requirements for the inductor switches 10 and also supplies power to the transceivers common circuitry. Power is derived from the voltage across the fixed inductor 32 and the power supplied from the inductor switch 10 to the transceiver 14 is isolated from the inductor switch power supply 34 using a dc-dc converter 35 .
When the inductor switch control signal 37 is on, the inductor switch presents a nominal impedance when the applied voltage is in the direction of the modulation polarity 39 . Whilst when the control signal 37 is off, the impedance of the fixed inductor 32 is presented across the terminals 29 , 30 . This allows the control signal 37 to modulate the current flow through the inductor switch 10 such that it can transmit information.
The variable inductance 9 is made from a combinations of inductor switches 10 , in this embodiment four such inductor switches have been used, which can be switched to set the impedance to any one of five values as detailed below in Table 1:
TABLE 1
No of
Transceiver Inductance
Inductor
+ve half
−ve half
Binary
Switches ON
cycle
cycle
State
0
Zf + 4*Zv
Zf + 4*Zv
Null
1
Zf + 3*Zv
Zf + 4*Zv
00
2
Zf + 2*Zv
Zf + 4*Zv
01
3
Zf + 1*Zv
Zf + 4*Zv
10
4
Zf
Zf + 4*Zv
11
Zf = fixed inductor 8 value
Zv = variable inductor 32 value
TABLE 2
No of
Loop Inductance
Inductor
+ve half
−ve half
Binary
Switches ON
cycle
cycle
State
0
Zft + 4*Zvt +
Zft + 4*Zvt +
Null
Zfr + 4*Zvr
Zr
1
Zft + 3*Zvt +
Zft + 4*Zvt +
00
Zfr + 4*Zvr
Zr
2
Zft + 2*Zvt +
Zft + 4*Zvt +
01
Zfr + 4*Zvr
Zr
3
Zft + 1*Zvt +
Zft + 4*Zvt +
10
Zfr + 4*Zvr
Zr
4
Zft + Zfr +
Zft + 4*Zvt +
11
4*Zvr
Zr
Zft = transmitter fixed inductor 8 value
Zvt = transmitter variable inductor 32 value
Zfr = receiver fixed inductor 8 value
Zvr = receiver variable inductor 32 value
Zr = receiver inductance fixed + variable
It can be seen from the information detailed in table 1 above that five distinct transmission currents can be generated, this is also illustrated in FIG. 5 . Reserving the state where all switches 10 are off as a null state, this leaves 4 transmission currents which allows 2 bits of information to be transferred by the variable impedance 9 . FIG. 5 shows a message on the positive polarity cycle of binary 00011011, a signal which has been created by sequentially, on each positive half cycle switching on 1 then 2 then 3 then 4 of the inductor switches 10 . The binary signal with a null, that is to say no inductor switches selected, preceding and following the signal, is decimal 27 . The decimal value 27 is the information that the microcontroller 19 sends to the receiver to indicate that the thermistor over-temperature detection device 15 has signalled a high value into the microcontroller 19 , or when the measurement device 20 has generated a signal that it has sent to the microcontroller.
The receiver for this message does not switch on the positive polarity; it is 180 degrees out of phase and the inductance of the transceiver acting as the receiver is fixed at Zf+4*Zv as listed in Table 2. Hence by measuring the lowest current through the transceiver the null signal value is known and by measuring the maximum current the changes in current between each of the transmitter states can be determined. This allows the receiver to recover the information in the current flow as transmitted by the opposing transceiver.
Where the voltage is insufficient to power the communications FIGS. 6 , 7 , 8 and 9 show alternative approaches. FIG. 6 adds a variable inductance 43 in one phase of the conductor to cause a load imbalance. FIG. 7 applies a phase voltage across the communication system by connecting the supply transceiver to one phase of the supply 44 . FIG. 8 applies a phase conductor voltage drop across the transceiver by connecting the transceivers 14 at either end 44 , 45 of the cable 5 .
FIG. 9 shows delta connected supply and load where a phase to phase voltage difference is applied across the communication system by connecting one transceiver to one phase 46 of the supply 44 and the second transceiver to another phase 48 at the motor end 45 . Other approaches to generating this communications voltage are possible. It will be understood that the voltage reference conductor may be a separate conductor.
To send information in the opposite direction is the same as described hereinabove.
The primary advantages of the present invention over those of existing systems is that the present invention removes the need to run a separate communication cable to the remote load and does not require the coupling of a communication power supply or signal to the 3 phase power system.
Other advantages are that the modulated current is not the motor current, but a much smaller earth link current thus improving the signal to noise ratio. Also by utilising the power supply as the carrier for the transmission system, this provides a greater amount of power available for the transmitter electronics compared to systems that use a coupled supply. Likewise, because there is no coupling it is possible to modulate the earth link current at a high rate, thus allowing a high data transfer rate to be achieved. A further advantage is that with the embodiments hereinbefore described the data rate transfer is greater or equal to the motor frequency, that is 50 bits pe second for 50 Hz, and is also independent of any oscillations or changes in the motor current. | A power line communications technique (PLC) is disclosed which allows communications across any three phase electric system by modulating the impedance through earth between any two points of differing voltage on the electrical system in order to use the power supply as the communications power source thereby using the power supply current as the communications carrier. No additional coupled communications source is required and modulation of an earth link current at the power frequency is especially suitable for remote electrical loads, such as an oil well electric submersible pump, where it is most cost effective to only have the three power conductors and no neutral nor signal wires in the power cable. Embodiments of the invention are described. | 7 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/958,911 filed Jul. 10, 2007, the disclosure of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the invention
[0002] The field of the invention is the mechanical mixing of fluids or solids-laden slurries stored in vessels or tanks.
[0003] The process of mixing liquids stored in tanks has been extensively studied and is important in many industries, for example, chemical processing, municipal water treatment, mining, and oil well drilling. Similarly, the design of fluid driven turbines is well known including fluid driven “mud motors” designed for downhole use in well drilling applications. The technologies, however, have not heretofore been combined in a mixing apparatus.
OBJECTS OF THE INVENTION
[0004] It is an object of the invention to power a mixing impeller with a turbine. Powering a mixing impeller with a turbine has several potential advantages over prior art techniques. The working fluid for the turbine section can be the same fluid as the fluid being mixed because the working fluid exiting the turbine section can be discharged to the body of fluid being mixed. The apparatus can be installed inside of the vessel being mixed and can be completely submerged by floor mounting, eliminating the need for obstructing usable work space on the top of tanks as is common when installing top driven agitators. The combination would also eliminate the hazard and special precautions that must be taken for electrical motor-driven mixers when flammable fluids are being mixed. Also, a turbine driven mixer could be mounted in the bottom of the tank, reducing the required shaft length and the weight and the moment arm forces that must be supported by the bearings in the mixer. Additionally, using a working fluid drive would permit the mixing impeller to accelerate slowly at much lower shock and torque loads than in a direct driven turbine mixer.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to the mixing of fluids or slurries as required to maintain homogeneous fluid properties, blend constituents, and/or suspend solids. In a preferred embodiment, the invention comprises a submersible mixer assembly that utilizes a conventional multi-bladed mixing impeller powered by a fluid driven turbine through an r.p.m. reducer. The r.p.m. reducer permits each of the turbine and the mixing impeller to turn at near optimal rpm.
[0006] One embodiment of the invention is provided in the form of an apparatus comprising a turbine housing, a turbine shaft, rotor blades, a reduction gearbox, and impeller blades. The turbine housing defines an axial passage having an inlet end and an outlet end. The turbine shaft is axially mounted in the passage and has an output end protruding beyond the outlet end of the passage. A row of radially outwardly extending rotor blades is fixedly mounted to the turbine shaft between the inlet end and the outlet end of the housing. The r.p.m. reducer is mounted to the output end of the turbine shaft. A plurality of the impeller blades is mounted to the r.p.m. reducer.
[0007] In another embodiment of the invention, the just-described apparatus can be employed, in combination with a vessel, in a method for mixing a liquid-based mixture. The mixture is provided in the vessel. A turbine, coupled to a mixing impeller via reduction gearing, is positioned in the vessel, the mixing impeller being immersed in the mixture. Fluid is flowed through the turbine to drive the impeller and mix the liquid-based mixture.
[0008] The working fluid for the turbine is preferably the same fluid as that contained within the vessel being mixed. However, it can be from an outside source, or it can be fluid contained in a closed loop segregated from the process by shaft seals. The working fluid is forced by an external pump through the turbine stage(s) to deliver power to a speed reducing gearbox and the low speed output of the gearbox is rigidly attached to the mixing impeller. The working fluid exiting the turbine section is preferably discharged to the vessel being mixed where it commingles with the fluid being mixed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic illustration of a fluid circuit for a turbine driven mixing apparatus in accordance with an embodiment of the invention.
[0010] FIG. 2 is a cross sectional view of a turbine driven mixing apparatus in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] One embodiment of the invention is provided in the form of an apparatus comprising a turbine housing, a turbine shaft, rotor blades, an r.p.m. reducer, and impeller blades. The turbine housing defines an axial passage having an inlet end and an outlet end. The turbine shaft is axially mounted in the passage and has an output end protruding beyond the outlet end of the passage. A row of radially outwardly extending rotor blades is fixedly mounted to the turbine shaft between the inlet end and the outlet end of the housing. A row of radially inwardly extending stator blades is preferably fixedly mounted to the turbine housing at a position adjacent to the row of rotor blades and the apparatus more preferably comprises multiple rows of rotor blades and stator blades. The r.p.m. reducer is mounted to the output end of the turbine shaft. A plurality of the impeller blades is mounted to the r.p.m. reducer. The r.p.m. reducer will generally comprise a reduction gearbox and the impeller blades can be mounted to the outer surface of the reduction gearbox. Alternatively, where the reduction gearbox has an output shaft, the impeller blades can be mounted to it.
[0012] The reduction gearbox is preferably rotationally carried by the turbine shaft and the impeller blades revolve more slowly than the turbine shaft and about the same axis.
[0013] The reduction gearing can vary over a wide range depending on the application, but will generally be in the range of 3:1 to 30:1 and usually in the range of 6:1 to 15:1. By mounting the impeller blades to the reduction gearbox casing, the necessity of an output shaft seal for the reduction gearbox can be avoided. The reduction gearbox preferably has a generally cylindrical outside surface, and the impeller blades preferably extend radially outwardly therefrom, the gearbox casing serving as a hub for the impeller blades.
[0014] In the illustrated embodiment, a lower bearing pedestal is fixedly mounted in the turbine housing near the inlet end of the housing for rotationally carrying a lower end of the turbine shaft, and an upper bearing pedestal fixedly is mounted in the turbine housing near the outlet end for rotationally carrying an upper end of the turbine shaft. A support base structure is connected to an outer surface of the turbine housing to position the turbine housing so that the axial passage is vertically oriented and the inlet to the axial passage is spaced apart from a lower end of the support base structure.
[0015] In an alternative design, (not shown), the turbine is mounted to a support structure so that the axial passage is generally horizontally positioned. The turbine output shaft is connected to an r.p.m. reducer in the form of a right angle drive gearbox, preferably including reduction gearing. The impeller blades are connected to a vertically positioned output shaft of the reduction gearbox. When constructed in this manner, the resulting assembly has a low profile and is highly suitable for use in shallow tanks.
[0016] The apparatus is used in combination with a vessel and a pump. The vessel comprises a sidewall, a lower end closure, and an upper end closure. The support base structure is mounted to the lower end closure of the vessel to position the turbine housing, in the preferred embodiment, vertically within the vessel. The pump has an inlet and an outlet. When the turbine working fluid comprises recirculated mixture, a first conduit connects the inlet of the pump to a lower inside portion of the vessel, and second conduit connects the outlet of the pump to the inlet end of the turbine housing. A tubular shaft is preferably also provided. The tubular shaft connects the upper end closure of the vessel with an upper end of the gearbox. It is mounted to the upper end closure for rotational movement and the inside of the tube is accessible from outside the tank, to provide venting and a path to permit adding oil as needed to the gearbox. If desired, a gearbox totally sealed from the outside environment could be employed, for example, by providing it with an inside bladder to accommodate expansion and contraction of the oil to avoid unnecessarily stressing the gearbox seals.
[0017] FIG. 1 illustrates a loop circulation system consisting of a vessel 101 in which a fluid driven turbine mixing apparatus 102 is installed. A pump 103 circulates fluid to and from the vessel 101 by pumping through the mixing apparatus 102 . The pump inlet nozzle 104 has a flooded suction fluidly connected to the contents of the vessel 101 . The working fluid discharges from the mixing apparatus 102 into the vessel where the working fluid freely mixes with the fluid being mixed. This commingling of working fluid and fluid being mixed is preferred in some applications because the density of the working fluid will always match the density of the fluid being mixed.
[0018] In some applications, for example, the mixing of oil well drilling fluids, the fluid density will vary. It is important that shaft power delivered by the turbine increases proportionally to the density of the fluid being mixed, otherwise the rotational speed of the mixer impeller will slow as the required mixing torque increases with fluid density. When a centrifugal pump is used to deliver fluid at a specific head to drive the turbine, the centrifugal pump will draw more power from its prime mover to maintain constant discharge head as fluid density increases. Since working fluid density in a circulation system like that shown in FIG. 1 must have the same density as the fluid being mixed, the shaft power delivered by the apparatus will match the increased power requirements of the mixing impeller as fluid density varies provided the pump delivers nearly constant discharge head.
[0019] The power output or brake horsepower of a fluid turbine is given by:
[0000] P hpb =ηQh÷ 33000 [Eqn 1] Where: P hpb =brake horsepower η=efficiency ρ=fluid density (lb/ft 3 ) Q=volume flow rate (ft 3 /min) h=head (feet)
[0026] For fluid driven turbines, it is known that higher head and higher rotational speeds are conducive to higher efficiency. It also known as a general rule that when mixing fluids or suspending solid laden slurries with specific gravities close to 1.0 that roughly 1 to 2 horsepower per 1000 gallons of fluid will need to be delivered to the fluid when a rotating multi-bladed impeller is used to impart flow and shear. Many mixing impeller applications require the impeller to rotate at around 60 rpm.
[0027] The ability of a fluid driven turbine to generate the power required to drive a conventional 4 blade mixing impeller can be illustrated with the following example. If a centrifugal pump is used to pump a fluid with specific gravity 1.0 through the turbine section of the apparatus and that this pump delivers 600 gallons per minute (80 ft 3 /min) at 100 feet of head, then the brake horsepower of the turbine shaft can be calculated to be 11.4 horsepower, if efficient. It follows from the equation above that if the specific gravity of the fluid were 2.0, then the shaft power would be 22.8 horsepower. Obviously, the mixing apparatus is scalable and can be designed to work with different flow rates or a different heads so that a wide variety of process power requirements can be met.
[0028] Impeller power calculations are well known for the mixing of Newtonian fluids using conventional mixing impellers in standard vessel geometries. In that case, the power required can be calculated using:
[0000] P=N p ρN 3 D 5 [Eqn 2] Where: P=power in watts N p =power number (dimensionless but always less than 1.7) ρ=fluid density (kg/m 3 ) N=rotational speed (sec −1 ) D=impeller diameter (m)
The power requirement can be estimated for a 36 inch impeller turning 60 rpm by assuming that 1.7 is the power number for a given tank/impeller geometry. The power required to rotate the impeller at 60 rpm calculates to 9.9 horsepower for fluid of specific gravity of 1.0 which is less than the above calculated 11.4 shaft brake horsepower for fluid turbine mixing apparatus.
[0035] Therefore a mixing impeller can be driven by a fluid turbine with single stage centrifugal pump.
[0036] FIG. 2 illustrates a preferred embodiment of the invention. The discharge of an external pump, not shown, will be directed to the inlet nozzle 2 attached to the mixer base 1 . The fluid will flow through the turbine section 3 consisting of one or more stages (two are shown) of stator blade rows 11 and rotor blade rows 12 that are located inside the fluid conducting housing 4 containing the lower bearing pedestal 17 and the upper bearing pedestal 13 . Turbine shaft seals 10 protect the thrust bearings 9 located in the lower pedestal 17 from the working fluid. The upper bearings 14 are similarly protected by shaft seals 10 . The turbine shaft 8 transmits power to the gearbox 6 by using a male spline 15 to rotate the internal gearing (not shown) in the gearbox 6 . The gearbox 6 is connected to the turbine shaft 8 in a manner that prevents axial movement, but allows rotation in response to the power input from the turbine shaft 8 . A shaft seal 10 prevents working fluid ingress into the gear box 6 and oil loss from the gearbox 6 . Since the gearbox is filled with oil, a rotating vent pipe 7 maintains constant pressure in the gearbox 6 as the temperature of the oil varies. The vent pipe 7 terminates above the highest liquid level in the vessel and also permits oil level to be checked when the mixer is not in operation. The impeller blades 5 will be rigidly attached to the gearbox housing 6 and will impart flow and shear to the fluid being mixed as the gearbox 6 rotates. The speed reducing gearbox 6 permits the mixing impeller blades 5 to rotate at an optimal speed range around 60 rpm while the turbine blade rows 12 turn at a speed range around 600 rpm for higher efficiency.
[0037] The just-described apparatus can be employed, in combination with a vessel, in a method for mixing a liquid-based mixture. The mixture is provided in the vessel. A turbine, coupled to a mixing impeller via reduction gearing, is positioned in the vessel, the mixing impeller being immersed in the mixture. Fluid is flowed through the turbine to drive the impeller and mix the liquid-based mixture. In a preferred embodiment, the liquid-based mixture comprises a slurry and the fluid flowing through the turbine comprises recirculated slurry. In such case, the fluid flowing through the turbine is exhausted into the vessel. However, the working fluid can comprise only a component of the slurry, or it can be maintained totally separate from the slurry in a closed loop system.
[0038] While certain preferred embodiments of the invention have been described herein, the invention is not to be construed as being so limited, except to the extent that such limitations are found in the claims. | An improved fluid mixing apparatus is disclosed for the mechanical mixing of fluids or solids-laden slurries contained within a vessel. The invention utilizes a fluid driven turbine to drive a submerged mixing impeller through a speed reducing gearbox. A fluid conducting stator houses one or more turbine blade row(s) that are rotated as a working fluid is pumped through the turbine section by an external pump that circulates fluid at the required flow rate and head. The turbine shaft is rigidly connected to the high speed input shaft of a speed reducing gear box. The low speed output of the gearbox is rigidly attached to submerged mixing impeller(s). | 1 |
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for reducing the water content of water-containing, granular brown coal under the action of thermal energy and pressure on the material distributed in bed form. An apparatus of this type and the process carried out using it are described in patent application PCT/EP95/03814. The process comprises the features that
a) the brown coal is subjected to a mechanically applied initial surface pressure which is below the maximum surface pressure occurring in the process and at which thermal energy is supplied to the brown coal by steam which heats the brown coal, with condensation,
b) and then, without further supply of steam, the surface pressure is increased to at least 2.0 MPa to such an extent that the water present in the heated brown coal is expressed or squeezed out,
c) the brown coal being preheated by waste heat, prior to the supply of steam, and the waste-heat source used being hot water expressed from the brown coal from an earlier pass in the process.
The considerable engineering and energetic advantages produced in this process are described in the said patent application in which, in addition, the fundamental form of two apparatuses for carrying out the above-described process is dealt with, that is to say a double-belt press for receiving brown coal distributed flat in bed form, and a platen press which has a press ram and press base and which receives the brown coal distributed flat in bed form.
The journal "Braunkohle 39 (1987) issue 4, pages 78 to 87" describes another process for dewatering brown coal, the so-called "Fleiβner process",
in which brown coal is thermally dewatered by introducing superheated steam into the brown coal contained in an autoclave in a pressurized atmosphere of approximately 3.0 MPa.
The brown coal heated by this means, after emptying the autoclave, is transferred to a dry coal bunker, where the thermally dewatered brown coal is cooled by post-ventilation and thus post-dried. In conjunction with this process, during emptying of the autoclave, hot water contained therein is conducted away separately as waste water and fed to an adjacent autoclave to heat the cold brown coal contained therein.
SUMMARY OF THE INVENTION
The object underlying the present invention is to arrange the apparatus in such a manner that the hot water expressed or squeezed out from the brown coal and used as a waste-heat source is utilizable in a favourable manner in conjunction with a press for receiving the brown coal distributed flat in bed form. According to the invention this takes place using a press in which the brown coal is subjected to a mechanically applied initial surface pressure and which is furnished with orifices for feeding steam which, supplying thermal energy to the brown coal, heats this, with condensation, and the hot water contained in the heated brown coal is expressed for use as a waste-heat source, a vessel being provided for collecting the hot water, from which vessel the hot water is passed to the orifices in the press, and which is furnished with an inlet for the steam for expelling the hot water.
By using the press in combination with the vessel for collecting the hot water expressed from the brown coal, this hot water is made utilizable in a favourable manner as a waste-heat source, since the hot water is passed from the vessel to the orifices in the press, where it is then, under the steam pressure, forced through the brown coal distributed in bed form, for which purpose the steam is fed to the vessel via an inlet.
An expedient arrangement of the press is produced if this is constructed as a double-belt press and the intake area is furnished with a multiplicity of feed lances for feeding the steam and the hot water expressed from the brown coal, the hot water feed lances ending upstream of the steam feed lances. By means of the feed lances, both the steam and the hot water utilized as a waste-heat source may be introduced in a uniform distribution into the brown coal, more precisely in such a manner that, firstly, the feed lances for the hot water introduce this into the brown coal and subsequently the comparatively longer feed lances introduce the steam. This means that the brown coal is initially preheated by the hot water, utilizing its function as a waste-heat source.
For taking off the expressed water, through-holes are expediently provided in the lower conveyor belt. The through-holes are expediently arranged in such a manner that, downstream of the feed lances, there is first arranged a through-hole for cold water and subsequently a through-hole for hot water. At the former through-hole, cold water is then collected, since the hot water preheating the coal, by releasing its energy, is cooled down to the coal temperature. After the coal is further heated by the condensing steam, in the course of the pressing phase, the condensate and the coal water exits hot from the unit and is then passed out through the subsequent through-hole and fed back to the hot water lances.
Another advantageous possible arrangement for the press is given if it is constructed as a platen press having a press ram and press base and having steam-tight lateral pressure chamber walls, which platen press receives the brown coal distributed in bed form, at least the press ram being furnished with orifices for feeding hot water and steam and at least the press base being furnished with outlets for taking off the water expressed from the brown coal. The arrangement as a platen press permits a particularly uniform throughput of the hot water and the steam at definable pressures, since the platen press having a press ram and press base is substantially sealed off from the outside and thus the conditions in the platen press may be readily controlled by these.
In order to achieve the most uniform distribution possible of the hot water or the steam over the brown coal bed contained in the platen press, the orifices in the press ram for feeding the steam are distributed so closely together over the press ram that hot water exiting from the press ram and subsequent steam are distributed uniformly over the brown coal bed. In this manner, the hot water initially preheating the brown coal bed and then the subsequent steam are forced to flow through the brown coal bed with a substantially uniform flow front, so that the brown coal bed is uniformly heated over its entire surface.
In order in this process to distribute, especially, the influent hot water uniformly over the surface of the brown coal bed, the pressing side of the press ram and the press base are expediently furnished with a narrow-mesh screen, as a result of which the screen through-holes produced divide hot water, which passes through the press ram, and subsequent steam in such a manner that the hot water, flowing through the screen through-holes, and the steam are divided into fine jets in the manner of a shower. This avoids the hot water fed under pressure taking the form of relatively large jets, which in this case could divide the brown coal bed into channels in an uncontrolled manner, which would destroy the uniformity of the heating.
In order to utilize the energy content of the water exiting from the brown coal expediently, this water is passed to two outlets, of which one serves to carry away cold water and the other serves to transfer hot water to a vessel which is connected to the orifices in the press ram. The water exiting from the brown coal is initially cold water in the starting area of the process sequence which, with the increasing heating of the brown coal by the steam supply, continuously converts into hot water which is then utilized as a waste-heat source. The collection of the water exiting from the coal is divided in the apparatus according to the invention by means of two outlets, that is to say in such a manner that cold water, which cannot form a waste-heat source, is conducted away, whereas the hot water is transferred via a 2nd outlet into the vessel on which the steam acts. Under the steam pressure, the hot water is then to a certain extent forced out of the vessel and fed to the press.
Expediently, a temperature sensor is arranged upstream of the outlets, which temperature sensor controls the two outlets in such a manner that the cold water flows to one outlet and the hot water flows to the other outlet. If the sensor signals the presence of cold water, it permits this to flow off via an outlet. How-ever, if the temperature of the water increases above a defined value (hot water), the temperature sensor reverses the outlets in such a manner that the hot water then flows to the other outlet, from where it then flows to the vessel.
A control means, in particular a pump, is advantageously assigned to the hot water outlet which enables a pressure to be generated in the hot water feed line to the vessel such that the hot water is prevented from boiling in the feed to the vessel, as a result of which the temperature would immediately fall in this area. The hot water is thus kept at a pressure of approximately 2-3 bar, which corresponds to a mean boiling water temperature of approximately 130° C., which is then advantageously available for heating the brown coal at this level.
The outlets are expediently controlled using a 3-way valve, to the inlet of which flows the water expressed from the brown coal. The two other outlets then form the cold water outlet and the hot water outlet.
Upstream of the intake of the 3-way valve is advantageously connected a pressure-control valve which ensures that the expressed water has to overcome a certain resistance, as a result of which a pressure builds up during the expression of the water, e.g. 2-3 bar. On account of this pressure, the uniformity of the flow, in particular the duration of the action of hot water on the brown coal, can be controlled in a favourable manner. In addition, this enables the above-mentioned mean boiling water temperature of approximately 130° C. to be maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures show working examples of the invention. In the drawings
FIG. 1 shows a schematic diagram of the apparatus with a platen press as a basis;
FIG. 2 shows the platen press exerting the initial surface pressure;
FIG. 3 shows the platen press in the operating position during expression of the water contained in the heated brown coal;
FIG. 4 shows the apparatus with a double-belt press as a basis.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a block diagram of the entire apparatus based on a platen press having a press ram 10 and press base 9. Hot water or superheated steam is fed to this platen press via the feed line 40 and the water expressed or squeezed out by the platen press from the brown coal bed 14 situated therein is conducted away via the outlet line. Before further components belonging to the apparatus are considered in more detail, the platen press and its mode of action may first be described in more detail on the basis of FIGS. 2 and 3.
FIG. 2 shows a platen press having the press base 9 and the press ram 10. The press base 9 rests on supports 11 and 12 shown here only in outline. The press ram 10 is attached to the slide 13, which is raised and lowered by a press mechanism not shown here. The design of this platen press is in principle prior art.
The press base 9 is here constructed in a trough shape, so that the brown coal 14 can be introduced into it in a flat bed-form distribution. The press base 9 is furnished with water outlets 15 and the press ram 10 is furnished with feed orifices 21, so that, in the case of a closed platen press shown in FIG. 2, hot water HW and steam HD can be fed to the brown coal 14 via the feed orifices 21 and water exiting can be conducted away via the water outlets 15. The water outlets 15 are connected via the channels 17 shown as thin lines in the press base 9 to a collecting outlet, which is not shown, via which the expressed water can flow away.
The hot water HW and the steam HD are fed via the feed orifices 21, which are connected together by the channels 18 indicated as thin lines in the press ram 10. Hot water HW and steam HD are fed to the system of the channels 18 and the feed orifices 21 via the attached feed line 23, which leads to the vessel 24. Hot water HW is fed to the vessel 24 via the feed line 25 and steam HD is fed to the vessel 24 via the feed line 26, the valves 27 and 28 ensuring that the feed of hot water HW and superheated steam HD proceeds in the correct rhythm, the required amount and the correct sequence. The valve 29, by which the feed of superheated water HW and hot steam HD can be shut off, is inserted into feed line 23.
According to FIG. 2, the platen press is in a state in which the press ram 10 subjects the brown coal bed 14 to an initial surface pressure, with, as can be seen, the platen press having its press ram 10 and its press base 9 being just closed. In this operating phase, the valve 29 is opened, which then allows hot water HW, which had been introduced into the vessel 24 in advance, to flow out, and feeds it via the system of the channels 18 to the feed orifices 21. During this, a pressure exerted by the steam HD acts on the hot water HW indicated by the wavy line 30 in the vessel 24, which pressure continues into the vessel 24 via the feed line 26 when the valve 28 is open. Under the pressure of the steam HD, the hot water HW is fed uniformly to the brown coal bed 14 from the vessel 24 via the feed line 23 and the feed orifices 21 and forced through the brown coal, the hot water running off via the outlets 15. This forcing through of the hot water proceeds until the store of water in the vessel 24 is exhausted, whereupon immediately thereafter the steam HD then flows through the brown coal and heats this in the desired manner by condensation. At the end of this operating phase, that is at a sufficient temperature level of the brown coal, further feed of steam is blocked by a valve 29, whereupon the surface pressure in the platen press is increased to at least 2.0 MPa.
This operating phase is shown in FIG. 3, in which the press ram 10 has fallen further with respect to its position shown in FIG. 1, expressing the water contained in the brown coal, with compression of the brown coal bed 14. The expressed water which has a temperature corresponding to the heated coal bed 14 is then utilized in the above-mentioned manner as a waste-heat source and is fed as hot water to the vessel 24 via the feed line 25.
The process of dewatering the brown coal bed 14 is thus completed, so that the brown coal can be removed from the subsequently opened platen press.
The apparatus together with its components provided overall may now be described with reference to FIG. 1.
During the operating phase described in conjunction with FIG. 2, in which phase the brown coal bed 14 is subjected to an initial surface pressure, hot water HW is fed to the brown coal bed 14 via the feed line 40 from the vessel 30, which hot water flows uniformly flat through the coal bed line 14 and heats this in the context of a preheating. The hot water exiting in the course of this via the outlet line 41 is, as long as the sensor TIC1 indicates a temperature which does not fall below, for example, 130° C., fed via the pump 42, which is switched on by the sensor, to the feed line 25 which leads to the vessel 30 via the valve 27. However, if the TIC1 determines that the temperature has fallen below its threshold, that is, for example, 130° C., it switches the pump 42 off and feeds what is thus determined to be cold water via the pressure-control valve 43 to the 3-way valve 44 which conducts away the cold water via its outlet 45. The further outlet 46 is considered in more detail below.
When the platen press assumes the position shown in FIG. 3, owing to further descent of its press ram 10, expression of the water situated in the heated coal bed 14 then takes place, which water in turn exits as hot water HW via the outlet line 41 and is passed on in the manner described above.
The vessel 30 receives on the one hand the above-mentioned hot water HW via the feed line 25, and in addition superheated steam HD via the 3-way valve 47 which is introduced into the vessel 30 via the feed line 26. The 3-way valve 47 in this case assumes the task of the valve 28 shown in FIG. 2. The superheated steam HD forces the hot water situated in the vessel 30 out from this, namely via line 23, the temperature of the hot water exiting via the line 23 being measured by the temperature sensor TIC2. As long as this temperature sensor measures the influx of hot water into the line 23, it permits superheated steam HD to flow into the vessel 30 via the 3-way valve 47 in the manner described above and the hot water fed via the line 23 to flow into line 40 via the 3-way valve 48, so that the hot water, as mentioned above, enters the press ram 10.
When the hot water HW situated in the vessel 30 has been completely forced out of the vessel 30 by the steam HD, the temperature sensor TIC2 then determines an appropriate temperature level at the line 23 at which it switches over the two 3-way valves 47 and 48 in such a manner that the steam then flows through the 3-way valve 47 in the direction towards the 3-way valve 48 and is fed from this directly to the feed line 40. The steam HD then assumes in the platen press its function described above of heating the brown coal bed 14.
In FIG. 1, as an alternative, a path is shown for the hot water conducted away at outlet line 41, which path proceeds via line 49. When the presence of hot water in line 41 is detected by the temperature sensor TIC1, the 3-way valve 44 is switched to allow passage to line 49, so that the hot water passes directly to line 25. In order that no pressure drop, and thus a falling temperature, can occur during this in outlet line 41, the pressure-control valve 42 already mentioned above is provided upstream of the 3-way valve 44, which pressure-control valve ensures the maintenance of a minimum pressure in the outlet line 41, e.g. 2-3 bar.
Instead of the platen press, having the press ram 10 and the press base 9, depicted in FIG. 1, the double-belt press shown in FIG. 4 can also be used, which may be described below.
FIG. 4 shows the brown coal bunker 1, which contains brown coal which has been precrushed to a defined particle size. Steam feed lines or hot water feed lines or heat exchange surfaces, which enable preheating of the coal, can be built into the coal bunker 1. The precrushed brown coal is distributed from the coal bunker 1 in bed form onto the lower conveyor belt 2, shown in dashed lines, which transports the coal in the direction of the arrow. Above the conveyor belt 2 of the double-belt press shown, an upper conveyor belt 3 (pressing belt), which is likewise shown in dashed lines, moves forward in the direction of the arrow, the speed of which belt virtually matches that of the conveyor belt 2. The distance between conveyor belt 2 and conveyor belt 3 decreases in the running direction in the intake area 8 thus enables the pressure to be increased on the coal bed 4. The conveyor belt 3, depending on the throughput rate and water content of the brown coal, is height-adjustable over its entire course via load-transmitting press elements 5. Between conveyor belt 2 and conveyor belt 3 there are arranged a multiplicity of steam feed lances 6 and 6a which penetrate into the moving coal bed 4, which is shown as dots, the outlet orifices of which steam feed lances end at a point in the intake area 8 in which the pressure on the coal is below the maximum surface pressure in the course of the conveyor belts 2 and 3. The steam exiting from the steam feed lances 6 and 6a gives off its heat to the coal and condenses in the course of this. A relatively uniform heating of the coal bed 4 is ensured by the multiplicity of the feed lances 6 of different lengths and arranged at different heights. Hot water HW is fed via the feed lances 6 and steam is fed via the feed lances 6a, the feed lances 6 for the hot water HW therefore ending upstream of the feed lances 6a for the steam HD. The shared feed of hot water HW and steam HD according to FIG. 1 via the feed line 40 is performed, in the case of the double-belt press according to FIG. 4, via the separate feeds 51 and 52, the feed 51 feeding the hot water HW to the feed lances 6 and the feed 52 feeding the steam HD to the feed lances 6a. In the context of FIG. 1, this means that the outlet of the 3-way valve 48 according to FIG. 1 either feeds hot water HW to the feed 51 or connects steam HD directly to the feed 52. The double-belt press according to FIG. 4 thus replaces the platen press shown in FIG. 1.
The parameters pressure and temperature can be set via the height-adjustable conveyor belt 3 and via the steam pressure and the temperature of the heating steam supplied according to throughput rate, particle size and water content of the brown coal. In the course of the first process section (intake area 8), the coal bed 4 is pressure-loaded from above via the conveyor belt 3 by continuously increasing mechanically impressed forces and is preheated by the hot water HW. After a maximum area loading, which is to be specified, has been reached, the consolidated coal bed 4 enters the subsequent process section in which the pressure exerted by the upper conveyor belt 3 is kept constant or varied only slightly. The action of pressure, in combination with the elevated temperature, means that free and released water can be expressed from the coal bed 4 and can be taken off in one or more stages via through-holes 7 on conveyor belt 2 and, optionally, additionally on conveyor belt 3. The hot water exiting from the through-holes 7 and 7a, or a part-stream of this water, is used to preheat the brown coal. The cold water exiting beforehand in the process is conducted away via the through-hole 7a. | Apparatus for reducing the water content of water-containing, granular brown coal under the action of thermal energy and pressure on the material (14) distributed flat in bed form using a press (9, 10) in which the brown coal is subjected to a mechanically applied initial surface pressure and which is furnished with orifices (21) for feeding steam (HD) which, supplying thermal energy to the brown coal, heats this, with condensation, and the hot water (HW) contained in the heated brown coal is expressed for use as a waste-heat source, a vessel (30) being provided for collecting the hot water (HW), from which vessel the hot water (HW) is passed to the orifices (21) in the press (9, 10), and which vessel is furnished with an inlet for the steam (HD) for expelling the hot water (HW). | 2 |
TECHNICAL FIELD
The present invention pertains to rearranging Clos networks. More particularly, this invention relates to a method and a system that finds a path through a Synchronous Optical Network or Synchronous Digital Hierarchy (SONET/SDH) communications cross-connect for several kinds of connections, including: multirate unicast unidirectional, multirate unicast bidirectional, multirate subnetwork connection protection unidirectional, multirate subnetwork connection protection bidirectional, and multirate multicast connections.
BACKGROUND OF THE INVENTION
Implementations of SONET/SDH circuit-switchcd cross-connect switching structures may be designed to be non-blocking by providing sufficient hardware resources. (SONET is the North American equivalent of the SDH transmission standard; a reference here to SDH is intended to be a reference to either SDH or SONET.) For example, a three-stage Clos-type switching structure is made non-blocking by providing at least a certain minimum number of middle stage switches. The cost of a switch is proportional to the number of middle stage switches.
Reducing the number of middle switches in the architecture increases the blocking probability. However, if a new connection is initially blocked, it may sometimes be completed by rearranging existing connections. A rearrangement is not allowed to interrupt existing connections. A factor that makes rearranging connections difficult in an SDH signal environment is the multirate and multicast nature of SDH signals.
The 155,520 kbit/s Synchronous Transport Module-1 (STM-1) is the basic building block in an SDH network. An STM-1 signal consists of overhead and payload bytes organized in a 125 microsecond frame structure. The information is conditioned for serial transmission on the selected media (e.g. optical fiber) at a rate synchronized to the network. At each network node where the signal is demultiplexed, information is processed byte-by-byte.
The STM-1 signal uses a so-called Virtual Container (VC)--an information structure defined by the International Telecommunications Union (ITU)--to serve various Plesiochronous Digital Hierarchy (PDH) data rates. There are several different-capacity virtual containers: a VC-4 signal can transport 139,264 kbit/s; a VC-3 signal can transport either 44,736 kbit/s or 34,368 kbit/s; a VC-2 signal can transport 6,312 kbit/s; and a VC-12 signal can transport 2,048 kbit/s. An STM-1 signal may contain various combinations of different virtual containers, such as a single VC-4, or three VC-3s, or two VC-3s and seven VC-2s. It is perhaps fruitful to liken virtual containers to Russian nesting dolls, to imagine that in an STM-1 signal, lower-capacity virtual containers may be "nested" in larger-capacity virtual containers.
Existing SDH Digital Cross-Connect Systems (DCSs) are usually non-blocking or nearly non-blocking, made so by using complex hardware. One kind of architecture often used for such a DCS is a three-stage Clos-type network, made up of three interconnected switching stages: an input stage, middle stage, and output stage.
In a general SDH network environment, a cross-connect switching system makes connections that differ in three categories.
Unicast or multicast. A unicast connection supports traffic between two endpoints, while a multicast connection supports traffic from one endpoint to a group of endpoints.
Unidirectional or bidirectional. In a unidirectional connection, data flows in only one direction: from a source to one or more destinations. In a bidirectional connection, both endpoints serve as both sources and destinations. Multicast connections can only be unidirectional. Bidirectional unicast traffic appears at a switch as two connections, one for each direction.
Protected or not protected. In SubNetwork Connection Protection (SNCP), unicast data is sent simultaneously on two disjoint paths. If one of the paths degrades or fails, the data may still be correctly received on the other path. For generality, the point at which the connection splits into two streams or joins back into a single stream can occur within the network and is not restricted to the endpoints. Thus, the connection consists of concatenated segments of single streams and disjoint paths. SNCP connections appear at the switch in one of two forms. If the switch is at a split point, then it must support a connection from one input to two outputs. If the switch is at a merge point, then it must support a connection from two inputs to one output. Some further constraints exist regarding the timing relationship between the two streams, such as that the two streams must be synchronized to allow merging to occur properly.
Each stage in a three-stage SDH switching network may have either time, space, or both time and space switching capabilities. An SDH signal is basically time division multiplexing at a byte level. Repositioning virtual containers in the same STM-1 payload is time switching. Moving virtual containers from one STM-1 payload to another is space switching.
Several algorithms for rearranging Clos networks are known, e.g., a routing algorithm for rearranging three-stage Clos networks for single-rate unicast traffic. The most relevant existing algorithm for rearranging Clos networks is Paull's change algorithm. See M. C. Paull, Reswitching of Connection Networks, Bell Syst. Tech. J., vol. 41, pp 833-855, May 1962. In Paull's change algorithm, when the input requested is in input switch I, and the output requested is in output switch O, the algorithm searches for a middle switch m available for the connection request. Sometimes the link from input switch I to middle switch m, and the link from output switch O to middle switch m are free at the same time. Then no rearrangements of existing connections are required.
If there is no middle switch m found, then a rearrangement is necessary. The rearrangement procedure uses two middle switches, A and B, where A is one of the middle switches that is free (unused) from input switch I to a middle stage, but is not free from output switch O to the same middle stage. B is one of the middle switches that is free from output switch O to the middle stage but is not free from input switch I to the middle stage. Freeing up bandwidth through middle switch A or B is possible by swapping some existing connections using middle switch A or B.
The existing procedures work only for single-rate unicast traffic, and do not work with multirate SDH switching. It is not possible to directly modify or extend Paull's change algorithm or any other known algorithm to work with SDH switching. SNCP, a new ITU standardized capability, cannot be implemented inside of existing switching procedures. The SDH multirate signal hierarchy in combination with multicast requirements forecasted in SDH networks do not allow existing procedures to be used. Hardware costs motivate a move toward more complexity in the switching procedure. Desired connection capabilities of SDH unicast unidirectional, unicast bidirectional, unicast unidirectional SNCP, unicast bidirectional SNCP, and multicast render existing procedures highly inefficient or non-functional.
SUMMARY OF THE INVENTION
The present invention is a procedure for making a new connection in a SONET/SDH digital cross-connect system when no free path through the switching hardware is available, by rearranging existing connections. This switching procedure looks for a path that provides the needed payload capacity for the requested connection, while requiring the least rearrangement of existing connections. All existing payload traffic continues through the digital cross-connect during the rearrangement.
The present invention is intended for use where there are insufficient middle switches in the cross-connect to make it non-blocking. In making new connections, the present invention rearranges existing connections without interrupting existing connections (hitless operation), and uses less hardware than existing rearrangement procedures require for the same non-blocking capability. Hitless operation is possible when one middle switch is reserved for rearrangement.
It is an object of the present invention to incorporate SNCP functionality into a procedure for SDH (and SONET) switching. Another object of the present invention is to switch as one intact signal structure the various hierarchical data structures of the SDH protocols, thus avoiding having to perform 63 independent switching actions on a VC-4 payload, 21 on a VC-3 payload, and 3 on a VC-2 payload. Another object is to prescribe how to rearrange connections in switching hardware with more than three stages.
When a new connection is requested, a search is made to see if there is an available path through the switch. This path hunt is a search for a group of consecutive switching slots that can pass the connection from the requested inputs on the switch to the requested outputs. VC-4, VC-3, VC-2, and VC-12 connections require 63, 21, 3, 1 consecutive time slots, respectively. An alternative to using a group of consecutive slots would be to allow fragmenting the slots, but this is not possible for switching in an SNCP enviromnent, because SNCP requires an intact comparison of the entire signal in the middle stage. So the present invention avoids fragmenting slots.
To represent the SDH signal hierarchy, it must be possible to represent all possible legal (properly nested) combinations of payloads in a single STM-1 link. An STM-1 signal can accept one VC-4, three VC-3s, twenty-one VC-2s, sixty-three VC-12s or any legal combination of those four virtual containers yielding the capacity of one STM-1. To represent the particular combination of virtual containers, i.e., to indicate which time slots are used, an STM-1 signal uses a data structure that includes 63 separate storage locations.
Instead of the usual 63 storage locations, the present invention uses a hierarchical storage method with a hierarchical data structure having 88 storage locations. Location 0 is reserved to indicate whether the STM-1 signal is being used as a VC-4 entity; locations 1, 2, and 3 are for VC-3s; locations 4 through 24 are for VC-2s; and locations 25 through 87 are for VC-12s. Each of the 88 locations contains a value that represents whether the location is used, not used, or hierarchically used, which means that a larger bandwidth signal, such as a VC-4, is using the bandwidth so that no smaller capacity signal may use it.
If a lower level channel C l is a member of a higher level channel C h , then C l is said to be under C h . For example, VC-12 channel 25 is under VC-2 channel 4, which is under VC-3 channel 1, which is under VC-4 channel 0.
The present invention always begins with a search for a new connection path that does not require rearranging existing connections. The particular combination of VCs making up the new STM-1 signal influences where the procedure begins this initial search. When a new connection is a VC-4 or a VC-3 signal, the search starts at middle switch 0, and moves progressively toward higher numbered middle switches. This procedure continues until a solution is found, or all middle switches up to and including m-1 have been considered. When a new connection is a VC-2 or a VC-12 signal, the search starts at middle switch m-1 and moves progressively toward lower numbered middle switches. If no solution is found, the rearrangement procedure is used to look for a solution.
The rearrangement procedure, called the Hierarchical Path Hunt with Rearrangement Algorithm (HPHRA), finds and frees a middle switch A and channel C to allow the new connection. The channel C through middle switch A is denoted A.C. The connections using blocked channels under C are queued. The connections using channels in the queue (A.C A1 , A.C A2 , A.C A3 , . . . , A.C Ak ) must be freed. The procedure needs to find a middle switch B and hierarchy channel C B1 denoted B.C B1 to free A.C A1 in the queue. To find B.C B1 , first the connection using A.C A1 is found. Then, if an available channel exists that can take the connection, the existing connection is moved to B.C B1 . In this case, only one rearrangement of A.C A1 to B.C B1 is required to free A.C A1 .
If the procedure cannot find a channel B.C B1 (which is more likely in a more heavily loaded cross-connect), then the channel having the largest available bandwidth, even though it is not sufficient, is used for B.C B1 . In this case, it is possible to need more than one rearrangement in order to make A.C A1 available for the new connection. Several connections using the channels under B.C B1 must be rearranged so that B.C B1 is completely empty, allowing the existing connection on A.C A1 to be moved into B.C B1 .
For example, suppose the procedure is searching for an available path for the conflicting connection using channel B.C a under B.C B1 . Assume the available path is through D.C a . Simply moving the connection from B.C a to D.C a can makc B.C a free. If no such available channel exists, then the existing connection on A.C A1 is moved to B.C B1 , and the used channels under B.C B1 are moved to A.C A1 .
Next, the conflicting connection using channel A.C a under A.C A1 is swapped with B.C b under B.C B1 by using a proper one-to-one mapping between all channels under A.C A1 and all channels under B.C B1 . The pairs (A.C Ai , B.C Bi ), where i=1, 2, 3, . . . , k, are found and rearranged until the queue is empty, i.e., until the channels A.C A1 , A.C A2 , A.C A3 , . . . , A.C Ak are all freed. Then A.C is free, and the new connection can be made through middle switch A and channel C.
Another object of the present invention is to provide switching service by rearrangement for five kinds of SDH connection: unicast unidirectional with and without SNCP, unicast bidirectional with and without SNCP, and multicast. Still another object of the present invention is to provide switching service by rearrangement for various SDH switching architectures, including a three-stage switch that has both time (T) and space (S) switching capabilities in the first and third stages, and only SNCP selection and space switching in the middle stage: a TS-S-TS switching network.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and also other objects, advantages and features of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, which illustrate specific embodiments of the invention. In the drawings:
FIG. 1 shows a three-stage Clos network, which is prior art;
FIG. 2 shows the hierarchical signal levels of an STM-1 signal according to the present invention;
FIG. 3 is a high-level flow-chart of the overall path hunt and rearrangement procedure according to the present invention; and
FIG. 4 is a more detailed flow-chart of the path hunt procedure according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a three-stage Clos network with N 1 inlets and N 2 outlets is shown. Each switching module 21 of the first stage, which comprises the first column of switching modules, has n 1 inputs and m outputs, while each switching module 23 in the third stage has m inputs and n 2 outputs. The switching modules 21 and 23 are also called simply input and output switches, and the entire digital cross-connect system 25 is sometimes called simply a switch. The number of input switches, r 1 , and the number of output switches, r 2 , are given by the equations: r 1 =N 1 /n 1 , and r 2 =N 2 /n 2 .
There is exactly one link 24 connecting each input switch 21 to each middle switch 22, and exactly one link connecting each middle switch 22 to each output switch 23. The network has r 1 input switches, m of the r 1 ×r 2 middle switches, and r 2 output switches. This type of network is denoted by ν(m, n 1 , r 1 , n 2 , r 2 ). If the network is symmetrical, n=n 1 =n 2 , r=r 1 =r 2 , and n r =N. A symmetrical network is denoted by the reduced notation ν(m, n, r).
Each switching module also has various input and output ports. For example, switch r 1 of the first stage has an input port 26 and output port 24 (which is also an input port for the middle switch m). From the view of the present invention, determining which ports to use is not necessary, because each switching module is built to automatically connect input ports to output ports to meet the higher-level supervision provided, for example, by the present invention. Thus, the present invention is not concerned with determining what input ports to connect to what output ports across a switching module 21 or 23, but it is concerned with which input ports (and time slots) to connect across to output ports on switching module 22.
The encoding of an STM-1 signal according to the present invention is shown in FIG. 2. In this 88-byte wide representation, each byte has a value that indicates whether the corresponding time slot is used, not used, or hierarchically used. If a byte other than the byte at location 0 is indicated as being used hierarchically, then a larger bandwidth signal is using the location. For example, the byte at location 0 indicates whether the bytes are to be regarded collectively as a VC-4 level entity (highest capacity payload); and the byte at location 2 indicates whether all of the bytes hierarchically under byte 2 are to be regarded as a single VC-3 level entity.
The overall cross-connect procedure 11 of the present invention is shown in FIG. 3. If a new connection request cannot find an available path through the cross-connect by using the path hunt procedure 12, which is shown in more detail in FIG. 4, an attempt to rearrange existing connections must be made. The rearrangement process 13, which is represented in pseudo-code below, moves some existing connections so that the new connection can be made.
Referring now to FIG. 4, the path hunt method 12 uses one of four procedures 16, 17, 18, or 19, depending on the level of the virtual container for which a new connection is needed. If the path hunt succeeds, then no rearrangement is required to service the new connection request, and the overall procedure 11 (see FIG. 3) directs, in process 14, that the found connection be made. Otherwise, the rearrangement procedure 13, disclosed below as pseudo-code, is used. If either the rearrangement procedure 13 or the path hunt method 12 is successful, a new connection is made through process 14. If a path cannot be found even through rearrangement, the overall procedure 11 reports blocking, through process 15.
The present invention organizes procedures for finding an available path into three algorithms--Hierarchy Path Hunt with Rearrangement Algorithms (HPHRA) I, II, and III--differing in the kinds of connection they provide. In the final rearrangement procedure, one of the three HPHRA algorithms is used to provide the needed connection. HPHRA-I handles the signal hierarchy for unicast connections only. HPHRA-II handles unicast and multicast connections. HPHRA-III provides the same path finding as HPHRA-II, but in the context of SNCP connections.
HPHRA-I finds a middle switch A and channel C to free for the new connection. The hierarchical channel C must be of the same VC-type capacity as the connection request. The channel C through middle switch A is denoted as A.C. The connections using the channels that are under C and are not free are queued. The channels in the queue (A.C A1 , A.C A2 , A.C A3 , . . . , A.C Ak ) must be freed.
For A.C A1 in the queue, the procedure needs to find a middle switch B and hierarchy channel C B1 , denoted as B.C B1 . To find it, first the connection using A.C A1 is found, and if an available channel that can take the connection in the current state exists, the channel becomes B.C B1 . In this case, only one rearrangement of A.C A1 to B.C B1 is required to make A.C A1 free. If the procedure cannot find such a channel, then the channel that has the largest available bandwidth (even though it is not enough) becomes B.C B1 . In this case, it is possible to need more than one rearrangement to free A.C A1 .
Some connections using the channels under A.C A1 and some connections using the channels under B.C B1 in the current state must be rearranged so that A.C A1 is freed. The conflicting channel A.C a under A.C A1 is swapped with B.C b under B.C B1 by using a proper one-to-one mapping between all channels under A.C A1 and all channels under B.C B1 . The pairs (A.C Ai , B.C Bi ), where i=1, 2, 3, . . . , k, are found and rearranged until the queue is empty. Then A.C A1 , A.C A2 , A.C.sub. A3 , . . . , A.C Ak are all free, so that A.C is free, and the new connection can be made through middle switch A and channel C.
To prevent extremely long searches, a maximum allowable rearrangement length is specified. The rearrangement length is defined as the number of swappings in the rearrangement process. If the current rearrangement length exceeds the maximum, then this trial is abandoned and another is attempted.
Usually more than one A.C is found for the rearrangement process. The A.C are sorted by the availability of bandwidth. The rearrangement process uses the A.C one-by-one until the trials using different A.C exceeds the allowed number of trials.
HPHRA-I can also handle a bidirectional unicast connection, since that can be considered two individual unicast connections in an SDH cross-connect. To do this, HPHRA-I is applied in turn to each unicast connection that makes up the bidirectional unicast connection. If one of the two unicast connections in the bidirectional unicast connection is blocked, the entire bidirectional unicast connection is considered blocked.
The rearrangement procedure that is the present invention can be expressed in high-level pseudo-code using the following variable definitions:
I: the input switch which includes the input port requested;
O: the output switches which include the output port destinations;
F r (I): the set of all free A.Cs in row I, where C is a channel in the same level of the traffic type (VC-4/3/2/12) of the connection requested; and
F c (J): the set of all free A.Cs in column J, where C is a channel in the same level of the traffic type (VC-4/3/2/12) of the connection requested.
In the pseudo-code, the notation I∩O is used in the usual way, to represent the intersection of the two sets I and O. In particular, the pseudo-code uses the expression
F r (I)∩F c (O)
to represent all available paths entering from the input switch I (which in a two-dimensional representation of the switching problem would be a certain row), passing through the middle stage, and emerging from the output switch O (which in a two-dimensional representation of the switching problem would be a certain column).
HPHRA-I can be expressed in high-level pseudo-code.
Procedure HPHRA-I;
Step 1;
Read connection/disconnection request;
Step 2;
If disconnection is requested
Go to Step 5;
If connection is requested
If connection type is unidirectional unicast
Go to Step 3;
If A.C is found {Comment: rearrangement process is successful}
Go to Step 5;
Else {Comment: rearrangement process is unsuccessful}
Report Blocking;
Go to Step 1;
If connection type is bidirectional unicast
{Comment: the first unicast of the bidirectional unicast connection}
Go to Step 3;
If A.C is found
{Comment: rearrangement process of the first unicast is successful}
Establish the first unicast connection;
{Comment: now, the second unicast of the bidirectional unicast}
Go to Step 3;
If A.C is found
{Comment: rearrangement process of the second is successful}
Go to Step 5;
Else
{Comment: rearrangement process of the second is unsuccessful}
Remove the first unicast connection;
Report Blocking;
Go to Step 1;
Else
{Comment: rearrangement process of the first unicast is unsuccessful}
Report Blocking;
Go to Step 1;
Step 3;
Evaluate F r (I)∩F c (O)
If F r (I)∩F c (O) is NOT empty;
A.C←Pick one in F r (I)∩F c (O);
{Comment: packing method is used to find A.C}
Else
Go Rearrangement -- Unicast;
Step 4;
If Rearrangement -- Unicast is successful
{Comment: the intersection is not empty now}
Go to Step 3;
Else
Go to Step 2;
Step 5;
Establish connection/disconnection;
Go to Step 2;
End HPHRA-I.
Rearrangement -- Unicast;
{Comment: this procedure tries to make A.C free}
Step 1;
Find MAXX.Ys that have the MAX largest values in |F r (I)∩F c (O)|;
{Comment: MAX is the maximum number of A.Cs that will be tried}
Sort X.Ys by the availability of bandwidth;
While MAX>0
A.C←first element of sorted X.Ys;
Go to Step 2;
If rearrangement is successful
Return REARRANGED;
Else
Decrement MAX;
Return BLOCKED;
{Comment: the set of X.Ys is exhausted, and the rearrangement is still unsuccessful}
Step 2;
Do Rearrangement -- Row for I;
If Rearrangement -- Row is successful
Do Rearrangement -- Column for O;
If Rearrangement -- Column is successful
Report rearrangement is successful;
Else
{Comment: rearrangement for column was not successful}
Report rearrangement failure;
Else
{Comment: rearrangement for row was not successful}
Report rearrangement failure;
Go to Step 1;
End Rearrangement -- Unicast.
Rearrangement -- Row/Rearrangement -- Column;
{Comment: this part will be finished when two queues, Needed -- Channels -- Q and SWAP -- Q are empty. Needed -- Channels -- Q has channels that are supposed to be free and SWAP -- Q has rows and columns that will have to be visited to free the hierarchical channels in queue Needed -- Channels -- Q.}
Step 1;
If Rearrangement -- Row
Put all channels (A.C Ak ), k=1, 2, 3, . . . that are under A.C and currently used in row I, in queue Needed -- Channels -- Q;
If Rearrangement -- Column
Put all channels (A.C Ak ), k=1, 2, 3, . . . , that are under A.C and currently used in column O, in queue Needed -- Channels -- Q;
Step 2;
If Needed -- Channels -- Q is empty
Go to Step 6;
Else
A.C A ←first element of Needed -- Channels -- Q;
Remove the first element of Needed -- Channels -- Q;
If number of swapped connections exceeds maximum rearrangement lengths
{Comment: blocking decision is made here}
Report Blocking;
Go to Step 7;
Else
Find B.C B ;
Step 3;
If A.C A is a fully available channel for swapping
Move the connection using A.C A with B.C B ;
Else
Locate the connection using A.C A ;
Put the location in queue SWAP -- Q;
Step 4;
If queue SWAP -- Q is empty
Go to step 2;
Else
ROW←The row having A.C A in the first element of SWAP -- Q;
COL←The column having A.C A in the first element of SWAP -- Q;
{Comment: connection in the first element of SWAP -- Q}
Remove the first element of SWAP -- Q;
Step 5;
For all rows
For all channels
If a connection containing A.C a in COL that is under A.C A exists
Find B.C b ;
If B.C b is fully available
Move the connection using A.C a to B.C b ;
{Comment: no ripple effect will occur}
Else
Move the connection A.C a to B.C b ;
Locate A.C a ;
{Comment: find ROW and COL for A.C a }
Put the location in SWAP -- Q;
{Comment: ripple effect is expected. The conflicting channel is queued in SWAP -- Q.}
For all columns
For all channels
If a connection containing A.C a in ROW that is under A.C A exists
Find B.C b ;
If B.C b is fully available
Move the connection using A.C a to B.C b ;
{Comment: no ripple effect will occur}
Else
Move the connection A.C a to B.C b ;
Locate A.C a ;
{Comment: find ROW and COL for A.C a }
Put the location in SWAP -- Q;
{Comment: ripple effect is expected. The conflicting channel is queued in SWAP -- Q.}
Go to Step 4;
Step 6;
Return that the rearrangement process is successful;
Step 7;
Return that the rearrangement process has failed;
End Rearrangement -- Row/Rearrangement -- Column.
Since the unicast connection type is a special case of the multicast connection type, a rearrangement algorithm that can handle the multicast connection type will also handle the unicast connection type. The HPHRA-II procedure can handle unidirectional unicast, bidirectional unicast, and multicast connection types.
The idea of HPHRA-II is based on applying HPHRA-I recursively to all output switches that are destinations. A multicast connection type is defined as a connection with a single source and at least two destinations. Sometimes more than one port destination is included in the same output switch, and this connection is also considered a multicast connection type, even though only one output switch is involved.
In HPHRA-II, the middle switch A and the channel C are selected by finding the combination that has the greatest free bandwidth between the input switch and all the output switches involved. Step 1 in the procedure Rearrangement -- Multicast of the pseudo-code for HRHPA-II finds this A.C. If there is no A.C between the input switch and all output switches involved, the entire multicast connection is considered blocked.
In terms of pseudo-code, the HPHRA-II is shown below.
Procedure HPHRA-II;
Step 1;
Read connection/disconnection request;
Step 2;
If disconnection is requested
Go to Step 5;
If connection is requested
If connection type is multicast
{Comment: unicast is considered as a multicast connection with only one output.}
Goto Step 3;
If A.C is found comment: rearrangement process is successful
Go to Step 5;
Else {Comment: rearrangement process is unsuccessful}
Report Blocking;
Go to Step 1;
If connection type is unidirectional unicast
Go to Step 3;
{Comment: l=1 for a unicast connection}
If A.C is found {Comment: rearrangement process is successful}
Go to Step 5;
Else {Comment: rearrangement process is unsuccessful}
Report Blocking;
Go to Step 1;
If connection type is bidirectional unicast
{Comment: the first unicast of the bidirectional unicast connection}
Go to Step 3;
If A.C is found;
{Comment: rearrangement process for the first unicast is successful}
Establish the first unicast connection;
{Comment: the second unicast of the bidirectional unicast}
Go to Step 3;
If A.C is found;
{Comment: rearrangement process for the second is successful}
Go to Step 5;
Else
{Comment: rearrangement process of the second is unsuccessful}
Remove the first unicast connection;
Report Blocking;
Go to Step 1;
Else
{Comment: rearrangement process of the first unicast is unsuccessful}
Report Blocking;
Go to Step 1;
Step 3;
Evaluate F r (I)∩F c (O k ) for all k=1, 2, 3, . . . , l where l is the number of output switches in the destinations;
If F r (I)∩F c (O k ) is NOT empty
A.C←Pick one in F r (I)∩F c (O k );
{Comment: packing method is used to find A.C}
Go to Step 5;
Else
{Comment: The intersection is empty}
Go Rearrangement -- Multicast;
Step 4;
If rearrangement process is successful
{Comment: the intersection is not empty now}
Go to Step 3;
Else
Go to Step 2;
Step 5;
Establish connection/disconnection;
Go to Step 2;
End HPHRA-II.
Rearrangement -- Multicast;
Step 1;
Find A.C which has the largest value in |F r (I)∩F c (O k )| where k=1, 2, 3, . . . , l.;
{Comment: l is the number of output switches involved in the destination.}
Step 2;
Do Rearrangement -- Row for I;
{Comment: Rearrangement -- Row is in HPHRA-I}
If Rearrangement -- Row is successful
k=1;
While (k<l+1)
Do Rearrangement -- Column for O k ;
{Comment: Rearrangement -- Column is in HPHRA-I}
If Rearrangement -- Column is successful
Increment k;
Else
{Comment: rearrangement process has failed}
k=l+1;
If Rearrangement -- Column for all output switches involved in the destination is successful
Return rearrangement is successful;
Else
{Comment: rearrangement for the column(s) was not successful}
Return rearrangement failure;
Else
{Comment: Rearrangement -- Row for I has failed}
Return rearrangement failure;
End Rearrangement -- Multicast.
To provide SNCP service, unicast data can be sent simultaneously on two disjoint paths. If one path experiences failure, the data may still be received correctly on the other path. For generality, the point at which the connection splits into two copies or joins back into a single copy can occur anywhere within the network.
SNCP connections appear at the switch in one of two forms. If the switch is at a split point, then it must support a connection from one input to two outputs. If the switch is at a merge point, then it must support a connection from two inputs to one output. The merge of the two copies occurs in the middle stage switch. This means the two copies are compared in the middle switch. After the comparison, one copy, which is usually free from errors, is chosen and proceeds to an output stage switch. The inverse procedure, the splitting (copying) also occurs in the middle stage switch. The two copies are connected to output stage destinations. No comparison of the two copies is made in the splitting operation.
To make building hardware practical, some further constraints are imposed regarding the timing relationship between the two copies. There are three cases allowed in the timing relationships. Case 1 uses the same channel n (but different input stage switch to middle stage switch connection) for the two copies A and B. Case 2 and case 3 use different channels for the two copies, but the channels used must be adjacent to each other.
In a three-stage Clos network, two input ports and one output port are involved in making a 2×1 SNCP connection. The input switches with the input ports involved in the switching are represented by I 1 , and I 2 . If the input ports involved are on the same input switch, then I 1 is equal to I 2 . Then, case 1 is invalid, because the two copies cannot share the same channel. The output switch O contains the output port involved in the 2×1 SNCP connection.
Case 1 means that the link between input switch I 1 and a middle switch M, the link between I 2 and the middle switch M, and the link between the middle switch M and output switch O use the same channel n for a connection. If the link between input switch I 1 and middle switch M uses n and the link between input switch I 2 and middle switch M uses n+1 for the connection, the connection corresponds to a case 2 type timing relationship. If the link between input switch I 1 and middle switch M uses n+1 and the link between input switch I 2 and middle switch M uses n, the connection corresponds to a case 3 type timing relationship. These are the case classifications used in HPHRA-III.
HPHRA-I and HPHRA-II do not have rearrangement capability for 2×1 SNCP connections. The 1×2 SNCP connection can be handled by HPHRA-II, because the connection can be treated as a 1×2 multicast connection. There is no difference between the 1×2 SNCP connection type and a 1×2 multicast connection type if the legs branch out in the middle stage switch. However, since the 2×1 SNCP connections have a different format, the previous rearrangement algorithm cannot handle the 2×1 SNCP connection types. The two input ports should be connected to the same middle switch so that the two copies can be compared. Furthermore, to build practical hardware, allowable channel usages must be organized into the three cases described above. The choice of timing among the three different cases is applied to both the path hunt and the rearrangement process.
In terms of pseudo-code, the overall procedure for the Hierarchical Path Hunt with Rearrangement for SNCP (HPHRA-III) is as shown below.
Procedure HPHRA-III;
Step 1;
Read connection/disconnection request;
Step 2;
If connection is requested
If connection type is multicast, unidirectional unicast, bidirectional unicast,
1×2 SNCP
Use HPHRA-II;
If connection type is SNCP 2×1
Use Rearrangement -- 2×1 -- SNCP;
If connection type is bidirectional SNCP connection
Use HPHRA-I for 1×2 SNCP connection;
If successful
Go to Rearrangement -- 2×1 -- SNCP;
If NOT successful
Remove the 1×2 SNCP connection;
End HPHRA-III.
Rearrangement -- 2×1 -- SNCP,
Comment: the rearrangement of SNCP follows the trials in order. If the current trial is completed successfully, then the algorithm stops and reports the rearrangement is successful. Otherwise the next trial will be attempted. If all trials failed, blocking is reported.;
Step 1;
While trials are not exhausted and the current trial has failed
If Trial 1
Find A.C which has the most available bandwidth in I 1 ∩I 2 ∩O;
If Trial 2 or Trial 3
Find A.C which has the most available bandwidth in I 1 ∩O;
If Trial 4 or Trial 5
Find A.C which has the most available bandwidth in I 2 ∩O;
{Comment: A.C is the desired channel for rearrangement process for 2×1 SNCP}
Go to Step 2;
If rearrangements are successful
Report REARRANGED;
Else
Report BLOCKED;
Step 2;
If Trial 1 or Trial 2 or Trial 4
Rearrangement -- Row for I 1 with A.C;
If successful
Rearrangement -- Row for I 2 with A.C;
If successful
Rearrangement -- Column for O with A.C;
If Trial 3
Rearrangement -- Row for I 1 with A.C;
If successful
Rearrangement -- Row for I 2 with A.C+1;
If successful
Rearrangement -- Column for O with A.C;
If Trial 5
Rearrangement -- Row for I 2 with A.C;
If successful
Rearrangement -- Row for I 1 with A.C+1;
If successful
Rearrangement -- Column for O with A.C;
Go to Step 1;
End Rearrangement -- 2×1 -- SNCP.
The five different trials shown in the procedure Rearrangement -- 2×1 -- SNCP above are explained below:
Trial 1: The middle switch A and channel C with the most available bandwidth in I 1 ∩I 2 ∩O are found. After finding A.C, use rearrangement for row I 1 with the desired channel A.C. If successful, then the rearrangement for row I 2 is attempted with the same A.C. Rearrangement for the column is only attempted if the rearrangement for row I 2 is successful. If the rearrangements are completed, then channel C is free from the input switches I 1 and I 2 to output switch O through the middle switch A. The timing relationship of the channels used in the connection correspond to a case 1 type timing relationship.
Trial 2: Attempted only if trial 1 fails. In this trial, the middle switch A and channel C, which have the most available bandwidth in I 1 ∩O, is used. I 2 is not considered in selecting A.C. Except for the procedure for finding A.C, this trial is same as trial 1. The timing relationship is a case 1 type timing relationship.
Trial 3: Attempted only if trial 1 and trial 2 failed. The rearrangement for row I 1 tries to make A.C, which was found in trial 2, free. If successful, the rearrangement for row I 2 will try to make A.C+1 free. C+1 is the adjacent channel of C. The timing relationship of the channels used in this connection corresponds to a case 2 type timing relationship.
Trial 4: Attempted only if trial 1, 2, and 3 failed. A.C is the middle switch and channel which has the most available bandwidth in I 2 ∩O. I 1 is not considered in selecting A.C. Except for the procedure for finding A.C, this trial is same as trial 1 and 2. The timing relationship in this trial is a type timing case 1 relationship.
Trial 5: Attempted only if trail 1, 2, 3, and 4 failed. This trial is similar to Trial 3. Rearrangement for I 1 is attempted with A.C+1 and rearrangement for I 2 is attempted with A.C which was found in trial 4. The timing relationship is a case 3 type timing relationship.
Although the invention has been shown and described with respect to a best mode embodiment thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions in the form and detail thereof may be made therein without departing from the spirit and scope of the invention. The invention includes a cross-connect 25 embodying the above methodology. | A connection procedure for finding by rearrangement a path for multirate, multicast traffic through an SDH cross-connect with subnetwork connection protection. If no free path for a new payload through the SDH switching hardware is available, the switching procedure looks for a path that is adequate and blocked by the least existing payload capacity. If the hunt is successful, the procedure rearranges the existing connections to make possible a path for the new payload. The procedure does not interrupt the existing connections; thus it is a "hitless" procedure. Connections for existing payloads that must be moved to make way for the new payload are queued and the connection procedure is applied recursively, to each in turn, until the queue is empty. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims the benefit of U.S. Provisional Application No. 60/821,906, entitled “DAC DRIVER With Feedback Control Loop,” filed on Aug. 9, 2006, the contents of which are hereby incorporated by reference herein in its entirety.
FIELD OF TECHNOLOGY
The present disclosure relates generally to digital circuits, and more particularly, to circuits for converting signals that vary in a first voltage range to signals that vary in a second voltage range.
DESCRIPTION OF THE RELATED ART
Typical current steering digital-to-analog converters (DACs) comprise a plurality of cells, each cell selectively supplying a current to a current summing line based on the digital value that is to be converted. The total current selectively supplied by all of the cells corresponds to the digital value, and different digital values will result in different amounts of total current.
For instance, FIG. 1 is a block diagram of an example current steering DAC 100 having a plurality of cells 104 , 108 , 112 , and 116 . Each of the cells 104 , 108 , 112 , 116 includes an output coupled to a current summing line 120 . Digital data that is to be converted may be supplied to each of the cells 104 , 108 , 112 , 116 . Each of the cells 104 , 108 , 112 , 116 cells includes a current source and a switch that selectively, based on the digital data, applies current from the current source to the summing line 120 . The total current on the summing line 120 will correspond to the digital value, and different digital values will result in different amounts of total current on the summing line 120 .
FIG. 2 is a block diagram of an example cell 150 that may be utilized in the current steering DAC 100 of FIG. 1 . The cell 150 includes a current source 154 and a switch comprising a p-channel metal oxide semiconductor (PMOS) transistor 158 and a PMOS transistor 162 . A source of the transistor 158 is coupled to the current source 154 , and a drain of the transistor 158 is coupled to the summing line 120 . A source of the transistor 162 is coupled to the current source 154 , and a drain of the transistor 162 is coupled to ground. The cell 150 also includes logic 166 that receives the digital data that is to be converted and generates a switch control signal based on the digital data. The switch control signal is coupled to a gate of the transistor 158 and is coupled to an input of an inverter 170 . An output of the inverter 170 is coupled to a gate of the transistor 162 .
In operation, the logic 166 will generate either a low signal (e.g., 0 volts) or a high signal (e.g., 1.2 volts) depending upon a value of the digital data. If a value of the digital data results in the logic 166 generating a low signal, the transistor 158 will be turned ON. Additionally, the inverter 170 will generate a high signal, and thus the transistor 162 will be turned OFF. This will result in the current source 154 being coupled to the summing line 120 . Thus, the current source 154 will supply its current to the summing line 120 . On the other hand, if a value of the digital data results in the logic 166 generating a high signal, the transistor 158 will be turned OFF. Additionally, the inverter 170 will generate a low signal, and thus the transistor 162 will be turned ON. This will result in the current source 154 being coupled to ground. Thus, the current source 154 will not supply any of its current to the summing line 120 .
SUMMARY OF THE DISCLOSURE
In accordance with one aspect of the disclosure, a circuit to convert a voltage range of a control signal comprises a first switch to selectively couple, based on the control signal, an output node to a first reference voltage when the output node is to be in a first state, and a second switch to selectively establish, based on the control signal, a second reference voltage when the output node is to be in a second state, the second state being a logical complement of the first state. The circuit also comprises a feedback control loop coupled to the output node to maintain the second reference voltage in response to voltage fluctuation at the output node. The feedback control loop includes a current mirror and a transistor coupled to the current mirror, wherein the transistor is controlled by feedback from the output node to modify a biasing current established by the current mirror to thereby counteract the voltage fluctuation.
In accordance with another aspect of the disclosure, a driving circuit to generate an output signal for a digital-to-analog converter cell in accordance with a control signal includes a first switch to selectively couple, based on the control signal, an output node to a first reference voltage when the output signal is to be in a first state. The driving circuit additionally includes a second switch to selectively establish, based on the control signal, a second reference voltage when the output signal is to be in a second state, the second state being a logical complement of the first state. The driving circuit further includes a feedback control loop coupled to the output node to maintain the second reference voltage in response to voltage fluctuation at the output node. The feedback control loop comprises a current mirror and first and second transistors coupled to the current mirror. The first transistor is coupled to the output node to be controlled by feedback from the output node to generate a bias voltage for the second transistor. The second transistor is coupled to the current mirror to modify current flow through a first branch of the current mirror in response to the feedback such that mirrored current through a second branch of the current mirror modifies a biasing current to counteract the voltage fluctuation.
In accordance with yet another aspect of the disclosure, a cell of a current-steering digital-to-analog converter includes a current source, and a p-channel metal oxide semiconductor (PMOS) transistor having a source coupled to the current source and a drain coupled to a current summing line. Also, the cell includes a driver circuit having a control input and an output node to drive a gate of the PMOS transistor. The driver circuit comprises a first switch to selectively couple, based on the control input, the output node to a first reference voltage when the cell is to be in a first state, and a diode coupled to the output node to establish, based on the control input, a second reference voltage for when the cell is to be in a second state, the second state being a logical complement of the first state. The driver circuit additionally comprises a feedback control loop coupled to the output node and the diode and comprising a current mirror to adjust a biasing current to be provided to the diode to counteract voltage fluctuation at the output node.
In accordance with still another aspect of the disclosure, a method for converting a voltage range of a control signal includes selectively coupling, based on the control signal, an output node to a first reference voltage when the output node is to be in a first state, and selectively establishing, based on the control signal, a second reference voltage when the output node is to be in a second state, the second state being a logical complement of the first state. Additionally, the method includes maintaining the second reference voltage in response to voltage fluctuation at the output node based on feedback from the output node.
In accordance with still another aspect of the disclosure, a circuit for converting a voltage range of a control signal comprises means for selectively coupling, based on the control signal, an output node to a first reference voltage when the output node is to be in a first state, and means for selectively establishing, based on the control signal, a second reference voltage when the output node is to be in a second state, the second state being a logical complement of the first state. The circuit additionally comprises means for maintaining the second reference voltage in response to voltage fluctuation at the output node.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the disclosure, reference should be made to the following detailed description and accompanying drawing figures, in which like reference numerals identify like elements in the figures, and in which:
FIG. 1 a block diagram of an example current steering digital-to-analog converter (DAC);
FIG. 2 is a circuit diagram of a cell of the current steering DAC of FIG. 1 ;
FIG. 3 is a circuit diagram of another cell that may be utilized in a current steering DAC;
FIG. 4 is a circuit diagram of an example driver circuit that may be utilized in the cell of FIG. 3 ;
FIG. 5A is a block diagram of a hard disk drive system that may utilize a circuit such as the circuit of FIG. 4 ;
FIG. 5B is a block diagram of a digital versatile drive system that may utilize a circuit such as the circuit of FIG. 4 ;
FIG. 5C is a block diagram of a high definition television that may utilize a circuit such as the circuit of FIG. 4 ;
FIG. 5D is a block diagram of a vehicle that may utilize a circuit such as the circuit of FIG. 4 ;
FIG. 5E is a block diagram of a cellular phone that may utilize a circuit such as the circuit of FIG. 4 ;
FIG. 5F is a block diagram of a set top box that may utilize a circuit such as the circuit of FIG. 4 ;
FIG. 5G is a block diagram of a media player that may utilize a circuit such as the circuit of FIG. 4 ; and
FIG. 5H is a block diagram of a voice over IP device that may utilize a circuit such as the circuit of FIG. 4 .
DETAILED DESCRIPTION
FIG. 3 is a block diagram of an example cell 200 that may be utilized in a current steering DAC. The cell 200 includes a current source 204 and a switch comprising a p-channel metal oxide semiconductor (PMOS) transistor 208 and a PMOS transistor 212 . A source of the transistor 208 is coupled to the current source 204 , and a drain of the transistor 208 is coupled to a summing line 216 . A source of the transistor 212 is coupled to the current source 204 , and a drain of the transistor 212 is coupled to ground. The cell 200 also includes a driver circuit 220 that receives an input signal and generates two output signals based on the input signal. The input signal is indicative of whether the current source 204 should be coupled to or isolated from the summing line 216 . The input signal may be generated by logic such as the logic block 166 of FIG. 2 .
The two output signals control the transistors 208 , 212 to selectively couple the current source 204 to the summing line 216 . One of the output signals, OUT, is coupled to a gate of the transistor 208 . The output signal, OUTB, is coupled to a gate of the transistor 212 . The input signal coupled to the driving circuit 220 will vary between voltages levels for a typical CMOS device. For example, the input signal may vary between 0 volts and 1.2 volts. An input signal of approximately 0 volts may indicate that the current source 204 should be coupled to the summing line 216 , and an input signal of approximately 1.2 volts may indicate that the current source 204 should be isolated from the summing line 216 , for example. Alternatively, an input signal of approximately 1.2 volts may indicate that the current source 204 should be coupled to the summing line 216 , and an input signal of approximately 0 volts may indicate that the current source 204 should be isolated from the summing line 216 , for example.
The driving circuit 220 generates the output signals such that they vary in a range that is less than the range of that of the input signal. For example, if the input signal varies between approximately 0 volts and 1.2 volts, the output signals may vary between approximately 300 millivolts and 1.2 volts, for example, or some other desired range of reduced voltage range or swing. It has been found that, in at least some implementations, using such a reduced range reduces charge injection associated with the transistors 208 , 212 . It also has been found that, in at least some implementations, using such a reduced range tends to keep the transistors 208 , 212 biased in a desired region, such as in saturation. In some cases, the reduced voltage range may desirably maintain a more constant output impedance for the cell of the current steering DAC.
In operation, when the input signal is HIGH (in the standard CMOS range), the driver circuit 220 will generate the signal OUT to be HIGH (in the reduced range) and will generate the signal OUTB to be LOW (in the reduced range). Similarly, when the input signal is LOW (in the standard CMOS range), the driver circuit 220 will generate the signal OUT to be LOW (in the reduced range) and will generate the signal OUTB to be HIGH (in the reduced range). As a specific example provided merely for explanatory purposes, if the input signal is 1.2 volts, the driver circuit 220 will generate the signal OUT to be 1.2 volts and will generate the signal OUTB to be 300 millivolts. Continuing with this example, if the input signal is 0 volts, the driver circuit 220 will generate the signal OUT to be 300 millivolts and will generate the signal OUTB to be 1.2 volts.
FIG. 4 is a circuit diagram of one example of a driving circuit 300 that may be used as the driving circuit 220 of FIG. 3 . The driving circuit 300 includes a flip flop 304 . The flip flop 304 includes a data input coupled to the input signal and a clock input coupled to a clock signal. The clock signal may be a clock signal of a DAC for example. The flip flop 304 generates a Q signal and a QB signal. In the embodiments described below, the Q signal corresponds with the input signal, while the QB signal corresponds to the logical complement of the input signal. In alternative embodiments, the Q signal corresponds to the logical complement of the input signal, and the QB signal corresponds to the input signal, as either the circuit nomenclature or, for instance, the logic 166 ( FIG. 2 ) may be adjusted accordingly.
The driving circuit 300 also includes a PMOS transistor 308 having a source coupled to a reference voltage V DD , a drain coupled to a current source 310 , and a gate tied to the drain. The reference voltage V DD may be 1.2 volts, for example, or any other suitable reference voltage. A PMOS transistor 312 has a source coupled to V DD , a drain coupled to a drain of an n-channel metal oxide semiconductor (NMOS) transistor 314 , and a gate coupled to the Q signal. The transistor 314 has its gate tied to its drain such that, in operation, the transistor is arranged as a forward-biased diode in accordance with the current flow. The Q signal is also coupled to the gate of an NMOS transistor 316 , which has a source coupled to V SS , and a drain coupled to the source of the transistor 314 . The reference voltage V SS may be ground, for example, or any other suitable reference voltage. A pair of PMOS transistors 322 and 324 are arranged as a current mirror. When the transistor 316 is ON, the current mirror that includes the transistors 322 and 324 provides a biasing current for the transistor 314 .
The gate of the transistor 314 is coupled to the OUTB node, as is the gate of an NMOS transistor 318 , which also shares a common source with the transistor 314 . The drain of the transistor 318 is coupled to the drain of a PMOS transistor 320 , which is configured as one-half of a current mirror formed with the transistor 308 . The source of the transistor 320 is coupled to V DD .
The transistor 318 may be considered a part of a feedback loop that interacts with the transistor 314 to compensate for (i.e., counteract) voltage fluctuations on the OUTB node. As described below, the OUTB node may exhibit dynamic behavior associated with the capacitive coupling between the driving circuit 300 and the remainder of the current steering DAC. The feedback loop includes a pair of PMOS transistors 322 and 324 arranged as a current mirror. The branch of the current mirror having the transistor 322 sources an NMOS transistor 326 , while the other branch of the current mirror (i.e., having the transistor 324 ) provides the biasing current to the transistor 314 . More specifically, and as shown in FIG. 4 , the drain of the transistor 322 is coupled to the drain of the transistor 326 . The gate of the transistor 326 , in turn, is coupled to the node defined by the connection of the transistors 320 and 318 .
In some embodiments, the driving circuit 300 further includes an identical circuit for generating a logic signal on a node OUT based on the QB signal. That is, the driving circuit 300 shown in FIG. 4 may correspond with only half of the driving circuit utilized to generate the logic signals on separate OUT and OUTB nodes.
Operation of the driving circuit 300 will now be described. First, assume that the Q signal is LOW, and the QB signal is HIGH. In this state, the transistor 312 is ON, and the transistor 316 is OFF. Thus, the transistor 312 acts as a switch to pull up the node OUTB to approximately V DD . In cases with a circuit complementary to the circuit 300 , the QB signal is HIGH, thereby turning the transistor 312 OFF, and the transistor 316 ON. In this event, and as will be described in more detail below, the transistor 316 acts as a switch such that the output node is drawn down toward V SS , to a desired voltage above V SS . This voltage will be referred to as V MIN .
With reference again to the driving circuit of FIG. 4 , when the Q signal transitions to HIGH, the transistor 312 will turn OFF and the transistor 316 will turn ON. This will cause the OUTB node to discharge toward V SS via the discharge path formed by the transistors 314 and 316 . The degree to which the transistor 314 is forward biased as a diode establishes the resulting desired voltage V MIN . The amount of current flowing through the transistor 314 thus affects the gate-to-source voltage (V GS ) of the transistor 314 . The eventual voltage V MIN established for the node OUTB will accordingly approximate V GS of the transistor 314 . The node OUTB can be made to fall to the desired voltage V MIN by appropriately selecting the transistor 314 . A biasing current for the transistor 314 is set by the current mirror that includes the transistors 322 and 324 . Additionally, the node OUTB is maintained at the desired voltage V MIN by the operation of the feedback loop and the quiescent current flowing through the transistor 320 , as described below. The supporting quiescent current is, in turn, established via the current mirror formed by the transistors 308 and 320 , and determined by the current IREF specified by the current source 310 . In one specific implementation, the voltage V MIN may be approximately 300 millivolts. It is to be understood, however, that other values of V MIN may be utilized as well. For example, the voltage V MIN may be approximately 100 millivolts, 125 millivolts, 150 millivolts, 175 millivolts, 200 millivolts, 225 millivolts, 250 millivolts, 275 millivolts, 325 millivolts, 350 millivolts, etc.
When the driving circuit 300 resides in the state with the Q signal HIGH, the transistors 308 and 320 act as a current mirror to establish the quiescent current through the transistor 318 , as well as the gate voltage for the transistor 326 . The gate voltage for the transistor 326 is determined via the feedback control loop formed by the transistors 318 and 326 , and the current mirror having the transistors 322 and 324 . Generally speaking, the feedback control loop reacts to fluctuations of the voltage on the OUTB node to maintain a constant current flowing through the transistor 314 , and thereby counteract the output node fluctuations.
If the OUTB node is tending to increase, the transistor 318 starts to pull the gate of the transistor 326 closer to V SS , such that the current flowing through the branch having the transistors 322 and 326 decreases. This decrease is matched in the mirrored current through the transistor 324 in the other branch of the current mirror and, as a result, the current biasing the transistor 314 decreases. The V GS of the transistor 314 accordingly starts to fall, thereby counteracting the initial tendency of the voltage on the OUTB node to increase.
Conversely, if the OUTB node is starting to decrease, the gate of the transistor 326 is provided a higher voltage, such that the current flowing through both branches of the current mirror formed by the transistors 322 and 324 increases. With the biasing current to the transistor 314 now increasing, the V GS of the transistor 314 begins to increase to compensate for, and counteract, the initial decrease at the OUTB node.
Through these adjustments, the feedback control loop supports the current flowing through the biasing transistor 314 , thereby maintaining a constant V MIN . In so doing, the feedback control loop also helps to avoid output node fluctuations that would otherwise undesirably increase the output impedance of the driving circuit 300 . Fluctuations of the output node voltage may otherwise occur because the OUTB node is capacitively coupled to the output of the DAC 100 , which exhibits a dynamic voltage. If, as a result of the fluctuations, the current through the transistor 314 were to decrease dramatically, the impedance of the OUTB node would correspondingly increase to levels that may, for instance, detrimentally slow the transitions between logic states.
The continued operation of the feedback control loop while the driving circuit is in the LOW state may be supported by a very low quiescent current set by the current source 310 . For example, the quiescent current flowing through the transistors 318 and 320 may be about 0.5 μA. In other embodiments, the quiescent current may fall within the range from about 1 μA to about 5 μA. In still other embodiments, the quiescent current may fall within the range from about 0.4 μA to about 5 μA.
One of ordinary skill in the art will recognize many variations to the example circuit 300 are possible. For example, the flip-flop 304 may be omitted and/or replaced with circuitry generating complementary Q and QB signals. As another example, the example circuit 300 (or variations thereof) is not limited to implementation in a configuration in which the output node OUTB is generated by the input signal Q, but rather may, for instance, be implemented such that the principal output generated by the circuit 300 is the OUT signal.
A circuit such as described above may be utilized in a variety of devices that require the conversion of a logic signal into a signal having a reduced range. As just one example, such a circuit may be utilized in current steering DACs. More generally, such a circuit may be utilized in a variety of electronic devices such as communication devices, computation devices, storage devices, networking devices, measurement devices, etc. Referring now to FIGS. 5A-5H , a few specific examples of devices that may utilize a circuit such as such as the circuit 300 will be described.
For example, referring to FIG. 5A , a hard disk drive 500 may include a circuit such as the circuit 300 . For example, signal processing and/or control circuits, which are generally identified in FIG. 5A at 502 , may include a circuit such as the circuit 300 . For instance, signal processing and/or control circuits 502 may include one or more current steering DACs. In some implementations, signal processing and/or control circuit 502 and/or other circuits (not shown) in HDD 500 may process data, perform coding and/or encryption, perform calculations, and/or format data that is output to and/or received from a magnetic storage medium 506 .
HDD 500 may communicate with a host device (not shown) such as a computer, mobile computing devices such as personal digital assistants, cellular phones, media or MP3 players and the like, and/or other devices via one or more wired or wireless communication links 508 . HDD 500 may be connected to memory 509 , such as random access memory (RAM), a nonvolatile memory such as flash memory, read only memory (ROM) and/or other suitable electronic data storage.
Referring now to FIG. 5B , a circuit such as the circuit 300 may be utilized in a digital versatile disc (DVD) drive 510 . A circuit such as the circuit 300 may be utilized in either or both signal processing and/or control circuits, which are generally identified in FIG. 5B at 512 , and/or mass data storage 518 of DVD drive 510 . For instance, signal processing and/or control circuits 512 and/or the mass storage device 518 may include one or more current steering DACs. Signal processing and/or control circuit 512 and/or other circuits (not shown) in DVD 510 may process data, perform coding and/or encryption, perform calculations, and/or format data that is read from and/or data written to an optical storage medium 516 . In some implementations, signal processing and/or control circuit 512 and/or other circuits (not shown) in DVD 510 can also perform other functions such as encoding and/or decoding and/or any other signal processing functions associated with a DVD drive.
DVD drive 510 may communicate with an output device (not shown) such as a computer, television or other device via one or more wired or wireless communication links 517 . DVD 510 may communicate with mass data storage 518 that stores data in a nonvolatile manner. Mass data storage 518 may include a hard disk drive (HDD) such as that shown in FIG. 5B . The HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. DVD 510 may be connected to memory 519 , such as RAM, ROM, nonvolatile memory such as flash memory, and/or other suitable electronic data storage.
Referring to FIG. 5C , a circuit such as the circuit 300 may be utilized in a high definition television (HDTV) 520 . The HDTV 520 includes signal processing and/or control circuits, which are generally identified in FIG. 5C at 522 , a WLAN interface 529 , and a mass data storage 527 . A circuit such as the circuit 300 may be utilized in the WLAN interface 529 or the signal processing circuit and/or control circuit 522 , for example. For instance, the WLAN interface 529 and/or signal processing and/or control circuits 522 may include one or more current steering DACs. HDTV 520 receives HDTV input signals in either a wired or wireless format and generates HDTV output signals for a display 526 . In some implementations, signal processing circuit and/or control circuit 522 and/or other circuits (not shown) of HDTV 520 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other type of HDTV processing that may be required.
HDTV 520 may communicate with mass data storage 527 that stores data in a nonvolatile manner such as optical and/or magnetic storage devices. The mass data storage 527 may include one or more hard disk drives (HDDs) and/or one or more digital versatile disks (DVDs). At least one HDD may have the configuration shown in FIG. 5A and/or at least one DVD may have the configuration shown in FIG. 5B . One or more of the HDDs may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. HDTV 520 may be connected to memory 528 such as RAM, ROM, nonvolatile memory such as flash memory and/or other suitable electronic data storage. HDTV 520 also may support connections with a WLAN via a WLAN network interface 529 .
Referring now to FIG. 5D , a circuit such as the circuit 300 may be utilized in a control system of a vehicle 530 . In some implementations, a circuit such as the circuit 300 may be utilized by a powertrain control system 532 that receives inputs from one or more sensors such as temperature sensors, pressure sensors, rotational sensors, airflow sensors and/or any other suitable sensors and/or that generates one or more output control signals such as engine operating parameters, transmission operating parameters, and/or other control signals. For instance, the powertrain control system 532 may include one or more current steering DACs.
A circuit such as the circuit 300 may be utilized in other control systems 540 of vehicle 530 . For instance, control systems 540 may include one or more current steering DACs. Control system 540 may likewise receive signals from input sensors 542 and/or output control signals to one or more output devices 544 . In some implementations, control system 540 may be part of an anti-lock braking system (ABS), a navigation system, a telematics system, a vehicle telematics system, a lane departure system, an adaptive cruise control system, a vehicle entertainment system such as a stereo, DVD, compact disc and the like. Still other implementations are contemplated.
Powertrain control system 532 may communicate with mass data storage 546 that stores data in a nonvolatile manner. Mass data storage 546 may include optical and/or magnetic storage devices for example hard disk drives HDD and/or DVDs. At least one HDD may have the configuration shown in FIG. 5A and/or at least one DVD may have the configuration shown in FIG. 5B . One or more of the HDDs may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. Powertrain control system 532 may be connected to memory 547 such as RAM, ROM, nonvolatile memory such as flash memory and/or other suitable electronic data storage. Powertrain control system 532 also may support connections with a WLAN via a WLAN network interface 548 . The WLAN interface 548 may include a circuit such as the circuit 300 . For instance, the WLAN interface 548 may include one or more current steering DACs. The control system 540 may also include mass data storage, memory and/or a WLAN interface (all not shown).
Referring now to FIG. 5E , a circuit such as the circuit 300 may be utilized in a cellular phone 550 that may include a cellular antenna 551 . The cellular phone 550 includes signal processing and/or control circuits, which are generally identified in FIG. 5E at 552 , a WLAN interface 568 , and a mass data storage 564 . A circuit such as the circuit 300 may be utilized in the signal processing and/or control circuits 552 and/or the WLAN interface 568 , for example. For instance, the signal processing and/or control circuits and/or the WLAN interface 568 may include one or more current steering DACs. In some implementations, cellular phone 550 includes a microphone 556 , an audio output 558 such as a speaker and/or audio output jack, a display 560 and/or an input device 562 such as a keypad, pointing device, voice actuation and/or other input device. Signal processing and/or control circuits 552 and/or other circuits (not shown) in cellular phone 550 may process data, perform coding and/or encryption, perform calculations, format data and/or perform other cellular phone functions.
Cellular phone 550 may communicate with mass data storage 564 that stores data in a nonvolatile manner such as optical and/or magnetic storage devices for example hard disk drives HDD and/or DVDs. At least one HDD may have the configuration shown in FIG. 5A and/or at least one DVD may have the configuration shown in FIG. 5B . At least one HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. Cellular phone 550 may be connected to memory 566 such as RAM, ROM, nonvolatile memory such as flash memory and/or other suitable electronic data storage. Cellular phone 550 also may support connections with a WLAN via a WLAN network interface 568 .
Referring now to FIG. 5F , a circuit such as the circuit 300 may be utilized in a set top box 580 . The set top box 580 includes signal processing and/or control circuits, which are generally identified in FIG. 5F at 584 , a WLAN interface 596 , and a mass data storage device 590 . A circuit such as the circuit 300 may be utilized in the signal processing and/or control circuits 584 and/or the WLAN interface 596 , for example. For instance, the signal processing and/or control circuits 584 and/or the WLAN interface 596 may include one or more current steering DACs. Set top box 580 receives signals from a source such as a broadband source and outputs standard and/or high definition audio/video signals suitable for a display 588 such as a television and/or monitor and/or other video and/or audio output devices. Signal processing and/or control circuits 584 and/or other circuits (not shown) of the set top box 580 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other set top box function.
Set top box 580 may communicate with mass data storage 590 that stores data in a nonvolatile manner. Mass data storage 590 may include optical and/or magnetic storage devices for example hard disk drives HDD and/or DVDs. At least one HDD may have the configuration shown in FIG. 5A and/or at least one DVD may have the configuration shown in FIG. 5B . At least one HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. Set top box 580 may be connected to memory 594 such as RAM, ROM, nonvolatile memory such as flash memory and/or other suitable electronic data storage. Set top box 580 also may support connections with a WLAN via a WLAN network interface 596 .
Referring now to FIG. 5G , a circuit such as the circuit 300 may be utilized in a media player 600 . The media player 600 may include signal processing and/or control circuits, which are generally identified in FIG. 5G at 604 , a WLAN interface 616 , and a mass data storage device 610 . A circuit such as the circuit 300 may be utilized in the signal processing and/or control circuits 604 and/or the WLAN interface 616 , for example. For instance, the signal processing and/or control circuits 604 and/or the WLAN interface 616 may include one or more current steering DACs. In some implementations, media player 600 includes a display 607 and/or a user input 608 such as a keypad, touchpad and the like. In some implementations, media player 600 may employ a graphical user interface (GUI) that typically employs menus, drop down menus, icons and/or a point-and-click interface via display 607 and/or user input 608 . Media player 600 further includes an audio output 609 such as a speaker and/or audio output jack. Signal processing and/or control circuits 604 and/or other circuits (not shown) of media player 600 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other media player function.
Media player 600 may communicate with mass data storage 610 that stores data such as compressed audio and/or video content in a nonvolatile manner. In some implementations, the compressed audio files include files that are compliant with MP3 format or other suitable compressed audio and/or video formats. The mass data storage may include optical and/or magnetic storage devices for example hard disk drives HDD and/or DVDs. At least one HDD may have the configuration shown in FIG. 5A and/or at least one DVD may have the configuration shown in FIG. 5B . At least one HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. Media player 600 may be connected to memory 614 such as RAM, ROM, nonvolatile memory such as flash memory and/or other suitable electronic data storage. Media player 600 also may support connections with a WLAN via a WLAN network interface 616 . Still other implementations in addition to those described above are contemplated.
Referring to FIG. 5H , a circuit such as the circuit 300 may be utilized in a Voice over Internet Protocol (VoIP) phone 650 that may include an antenna 654 , signal processing and/or control circuits 658 , a wireless interface 662 , and a mass data storage 666 . A circuit such as the circuit 300 may be utilized in the signal processing and/or control circuits 658 and/or the wireless interface 662 , for example. For instance, the signal processing and/or control circuits 658 and/or the wireless interface 662 may include one or more current steering DACs. In some implementations, VoIP phone 650 includes, in part, a microphone 670 , an audio output 674 such as a speaker and/or audio output jack, a display monitor 678 , an input device 682 such as a keypad, pointing device, voice actuation and/or other input devices, and a Wireless Fidelity (Wi-Fi) communication module 662 . Signal processing and/or control circuits 658 and/or other circuits (not shown) in VoIP phone 650 may process data, perform coding and/or encryption, perform calculations, format data and/or perform other VoIP phone functions.
VoIP phone 650 may communicate with mass data storage 666 that stores data in a nonvolatile manner such as optical and/or magnetic storage devices, for example hard disk drives HDD and/or DVDs. At least one HDD may have the configuration shown in FIG. 5A and/or at least one DVD may have the configuration shown in FIG. 5B . The HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. VoIP phone 650 may be connected to memory 686 , which may be a RAM, ROM, nonvolatile memory such as flash memory and/or other suitable electronic data storage. VoIP phone 650 is configured to establish communications link with a VoIP network (not shown) via Wi-Fi communication module 662 .
While the present invention has been described with reference to specific examples, which are intended to be illustrative only and not to be limiting of the invention, it will be apparent to those of ordinary skill in the art that changes, additions or deletions in addition to those explicitly described above may be made to the disclosed embodiments without departing from the spirit and scope of the invention. | In a circuit to convert a voltage range of a control signal, a first switch selectively couples, based on the control signal, an output node to a first reference voltage when the output node is to be in a first state. A second switch selectively establishes, based on the control signal, a second reference voltage when the output node is to be in a second state, the second state being a logical complement of the first state. A feedback control loop is coupled to the output node to maintain the second reference voltage in response to voltage fluctuation at the output node. The feedback control loop includes a current mirror and a transistor coupled to the current mirror. The transistor is controlled by feedback from the output node to modify a biasing current established by the current mirror to thereby counteract the voltage fluctuation. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an actuator assembly which has a quick release ability.
2. The Prior Art
A quick release in an actuator is used for temporary release of the activation element for manual setting without the drive unit. Examples of the potential use of a quick release are in hospital beds, patient hoists, fire doors and other constructions where it is important, if not essential, to be able to spontaneously set the activation element.
Actuators with quick release function are well known, for example, EP 685 662 B1, WO 03/033946 A1 and WO 2006/039931 A1 and EP 577 541 B1 all in the name of Linak A/S. The first three documents relate to a quick release construction based on a releasable clutch spring around two cylinder parts. The last document EP 577 541 relates to a quick release construction where a gear can be displaced from engagement.
In some situations it is desirable or essential to activate another function as a result of the quick release. Generally, this may be activation of a power supply and/or controls for the actuator and/or activation of one or more actuators simultaneously with the release of the quick release.
The object of the invention is to provide a solution to the problem described.
SUMMARY OF THE INVENTION
This is achieved in the invention by designing an actuator assembly which includes at least one electrical switch which is activated when the quick release is released. The signal from the electrical switch(es) may be used for various purposes, such as activating a power supply and/or control from sleep mode, activating one or more actuators, or activating an external function such as an alarm, etc. The circuit, of which the switch is part, will typically be designed for the switch to close a circuit, but the circuit may also be designed for the switch to break the circuit. The electrical contact is appropriately mounted in the actuator so that it is activated by one or more of the moveable construction elements in the quick release. Most suitably, it is the construction elements in the release mechanism itself, but it may however also be construction elements in the coupling parts of the quick release, such as the gear in the quick release as defined in EP 577 541 or a spring end or cylinder part in the constructions with coupling springs.
An actual implementation of the actuator system, which relates to a bed equipped with an actuator assembly, where the actuator for the back rest section comprises a quick release with an electrical switch activated by the release of the quick release. The bed is further equipped with position determination in a suitable manner.
A linear actuator according to the invention will be described below with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 , shows a hospital bed with four actuators;
FIG. 2 shows an exploded view of an actuator with a quick release unit;
FIG. 3 shows a detailed view of the quick release unit;
FIG. 4 is a longitudinal section through another actuator;
FIG. 5 is a side view of the actuator of FIG. 4 , and
FIG. 6 is an exploded view of the quick release unit of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a hospital bed equipped with an actuator assembly comprising four actuators 101 - 104 , a control box 105 containing a power supply and a control; and a hand operation 106 and an operations panel (ACP) 107 at the end of the bed. The power supply consists of a low voltage unit, typically transformer-based, and a rechargeable battery pack. Two of the actuators 101 , 102 are for adjustment (profiling) of the base 108 carrying the mattress, while the other two 103 , 104 are for height adjustment of the upper frame 109 on which the base is mounted. The two last mentioned actuators also allow for tilting of the base frame over a transverse axis (Trendelenburg/Anti-Trendelenburg position).
FIG. 2 shows an actuator with a quick release construction of the type mentioned in WO 2006/039931, more exactly FIGS. 1-7. The main elements of the actuator are a cabinet in two parts 1 a , 1 b with a reversible electric motor, which through a worm gear drives a spindle 2 with a spindle nut 3 , on which an activation rod 4 (inner tube) is surrounded by a protective tube 5 (outer tube) is attached. Note that the motor is not shown in the drawing, but it is located in the perpendicular section 1 c of the cabinet. The motor shaft extends into a worm engaging a worm wheel 6 . The spindle 2 is seated in the cabinet with a ball bearing 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a hospital bed equipped with an actuator assembly comprising four actuators 101 - 104 , a control box 105 containing a power supply 105 a and a control 105 b ; and a hand operation 106 and an operations panel (ACP) 107 at the end of the bed (operation unit). The power supply consists of a low voltage unit, typically transformer-based, and a rechargeable battery pack. Two of the actuators 101 , 102 are for adjustment (profiling) of the base 108 carrying the mattress, while the other two 103 , 104 are for height adjustment of the upper frame 109 on which the base is mounted. The two last mentioned actuators also allow for tilting of the base frame over a transverse axis (Trendelenburg/Anti-Trendelenburg position).
The quick release construction, consisting of an inner and an outer coupling part 8 , 9 , where the inner coupling part 8 is mounted at the end of the spindle 2 , while the outer coupling part 9 is mounted in the worm wheel 6 . This worm wheel is on the side facing the front end of the actuator, designed with a hollow cylindrical part that accommodates the outer coupling part 9 for torque transfer with a spline connection.
In the back of the worm wheel is a circular disc with three legs protruding through the openings in the worm wheel into the hollow cylindrical part and guided there. In the upper part 1 b of the cabinet is a release mechanism 13 in a housing 14 with an entry for a cable (not shown) leading to an operating handle (not shown either). The release mechanism comprises an axle unit 15 , led down behind the circular disc 11 . At the end of the axle unit there is a cam 16 which is brought into contact with the disc 11 by turning the axle unit and the disc presses this forward towards the worm wheel. The axle unit is spring loaded with a spring 17 , to an inactive position, i.e., a position where the cam 16 is not in contact with the disc 11 . A ring 18 is attached at the upper end of the axle, to which the end of the cable leading to the operating handle is attached.
The outer coupling part 9 , connected to the worm wheel, has an internal torque transfer spline connection 21 a in the front. On the outer side of the coupling part 9 at the front end, in front of the spline connection to the worm wheel, there is a flange 22 .
The inner coupling part 8 has a narrow part 23 in the front to enable it to pass through the opening in the part of the spline connection 21 a placed in the outer coupling part 9 . The other part of the spline connection is part of the step between the narrow end 23 and the outer side of the coupling part. In the narrow part 23 there is a groove for a disc 24 , creating a flange.
The quick release is activated by operating the release mechanism, which turns the cam 16 on the axle unit 15 into contact with the disc 11 , which is then pushed forward. The spline connection 21 a , 21 b between the outer coupling part 9 and the inner coupling part 8 will thus be interrupted and the spline will rotate freely, independent from motor and transmission. The activation rod 4 of the actuator and therefore the element attached to it, will then be manually adjustable.
An electrical contact in the form of a micro switch is placed next to the turning axle 15 , and a cam opposite to cam 16 activates the micro switch at the same time as the quick release is activated. This sends an electrical signal through the cable connection to the control unit, which is brought from sleep mode, more precisely the power supply for the control is activated, that is, the part of the power supply comprising the rechargeable battery pack. By keeping the battery pack switched off until it is required, i.e. use ‘on demand’, means a substantial saving in the battery pack power. When the bed is connected to mains power, the low voltage unit is active. Placing the switch in the actuator itself has the advantage that further cabling is avoided and only a cable for the actuator is required.
When the bed is without mains power and the back rest section 110 , must be moved rapidly to the horizontal position, such as in the case of a patient with cardiac arrest, this is achieved by activating the quick release. Simultaneously the control is brought from sleep mode and the bed becomes fully operational. The leg section 111 may be moved to horizontal position and, if required, may be brought into Trendelenburg position.
In FIGS. 4-5 , the actuator shown is the same type as specified in WO 2006/039931 Linak A/S, specifically in FIGS. 8-15 , and this is referred to as part of the present application. In FIG. 4 to elements labeled 2 ′, 6 ′, 8 ′, 9 ′ and 14 ′ correspond to elements 2 , 6 , 8 , 9 and 14 in the FIGS. 2-3 embodiment. The quick release construction itself is shown in FIG. 6 . The release mechanism consists of a tilting element 27 , that takes an inclined resting position. An axially sliding element 28 with a hook at the end grabs the tilting element and is connected to the operating handle by a cable. By operating the handle, the element 28 is pulled upwards and brings the tilting element 27 to a vertical position, releasing the quick release as previously described.
The inner coupling part 8 is equipped with a magnetic ring 31 with four poles used to determine the position of the activation rod 4 . Two Hall-elements, or sensors, 33 a , 33 b are mounted on a small printed circuit board 32 in conjunction with this. The Hall-elements are activated when a pole passes these on rotation of the magnetic ring, thereby sending a signal to the control unit which, by means of a microprocessor, computes the position of the activation rod 4 based on the rotation, its direction and the thread pitch of the spindle. Because the two Hall-elements are angularly displaced in relation to the magnetic ring 31 , the rotation direction of the spindle can be detected (quadrature detection) and determines if signals must be added or subtracted depending on the extension or retraction of the activation rod 4 . As the magnetic ring 31 is mounted to the inner coupling part 8 , the ring 31 always rotates with the spindle, i.e., also in the situation where the spindle is released from the motor/transmission. In this way the position of the activation rod is known at all times, also after activation of the quick release.
The actuator illustrated in FIG. 2 may be similarly equipped with a magnetic ring on the inner coupling part and Hall-elements, hence the position of the activation rod is also known in this case, regardless of whether the quick release has been activated or not. | Actuator system comprising at least one actuator, a control unit, a power supply and an operations panel, where the actuator in a transmission between an activation element ( 4 ) and a reversible electric motor is inserted a quick release unit ( 13 ) for release of the activation element ( 4 ) from the electric motor and the part of the transmission between the motor and the quick release. The actuator comprises at least one electrical switch ( 30 ), activated with the quick release. The signal from the electrical switch(es) ( 30 ) may be used for various purposes, such as triggering a power supply from sleep mode, activating one or more actuators, or activating an external function such as an alarm etc. | 5 |
[0001] This application is a continuation-in-part of pending application Ser. No. 09/116,241, filed Jul. 16, 1998.
FIELD OF THE INVENTION
[0002] This invention relates generally to laser systems having application to such fields as micro-machining, drilling and marking. A primary characteristic of these lasers is their high-powered short-pulsed output, which in, for example, an industrial application, preferably machines the surface of a target or workpiece by an ablation technique. The invention also relates generally to laser systems which can serve in replacement of more expensive Nd based lasers, such as diode-pumped Q-switched Nd:YAG lasers and other lasers using Nd-based materials.
BACKGROUND OF THE INVENTION
[0003] It has been known in the prior art to use pulsed laser systems to effect such processes as diverse as metal machining and biological tissue removal. Of chief concern in these systems is the amount of “collateral damage” to the surrounding regions of the workpiece, or, in the case of biological uses, surrounding tissues. In the case of the machining of metallic workpieces, for example, laser pulses greater than 100 microseconds in duration will machine the workpiece at the cost of creating a significant pool of molten liquid which is ejected from the beam impact site. Cleanly machined features cannot be obtained with this machining technique owing to the tendency of the molten material to spatter the workpiece and/or freeze and harden on the workpiece itself. This effect is due, of course, to the transfer of a significant amount of heat into the workpiece material at the target zone and at surrounding areas as well. In the case of biological procedures, this heat transfer effect typically causes unacceptable collateral damage to the surrounding tissues.
[0004] A general but partial solution to this problem resides in the use of shorter pulse durations. With shorter pulses the target is heated more quickly and thus reaches the evaporation point before significant liquid is permitted to form. Thus, in this arena, the shorter Q-switched temporal pulse may find advantage in certain applications. The pulse widths of conventional Q-switched, solid state lasers used in micro machining is approximately 50-200 nanoseconds. This pulse width has for many cases proven to provide a reasonable balance between laser cost, machining accuracy and collateral effects such as the size of the heat-affected zone (HAZ), it being generally understood that the cost of laser systems of significant power increases greatly with the shortness of the period of the output pulse.
[0005] However, even in the above mentioned pulse width range, the degree of heat transfer into the material is unacceptable for many applications. Recently developed lasers reported at OE/LASE SPIE vol. 2380 pp 138-143 (1995) which generate pulses in the 8-20 ns range abate this problem to a degree, however since the threshold for ablation in the nanosecond range decreases as the reciprocal of the square root of the laser temporal pulse width, it is apparent that as the pulsewidth is further reduced, the range of potential applications broadens considerably.
[0006] With advances in pulsed laser systems, lasers having pulse widths well into the femtosecond regime have become available. At these ultrashort pulse widths, collateral damage to surrounding regions becomes almost negligible, because of the lack of significant heat transfer into zones outside of the immediate target area. Essentially, the material at the target is substantially instantaneously vaporized while the fleeting duration of the impact of the laser energy substantially eliminates the possibility of heat transfer into surrounding areas. In general, it is known that the heat penetration depth L is proportional to the square root of the product of the heat diffusion coefficient (specific to the material) and the pulse width t. Consequently, as the pulse width becomes shorter, the heat penetration depth decreases proportionately. With femtosecond pulses, ablation thus takes place before significant heat can be transferred into the material, so that little or no heat effected zone (HAZ) is created. U.S. Pat. Nos. 5,656,186 and 5,720,894, incorporated herein by reference, discuss the above effects generally, and disclose laser systems operating well into the femtosecond regime in some instances.
[0007] However, as previously mentioned, the costs associated with femtosecond-regime micro-machining lasers are not insignificant; they presently cost five to fifteen times more than the present nanosecond-regime micro-machining sources. Thus, there is a need in the industrial and medical fields for a micro-machining or marking laser which reduces the collateral damage problems of the prior art, yet has a cost comparable to the present sources. This goal has been achieved through the present invention, which, through the use of a novel and highly efficient combination of Q-switching and Yb fiber laser techniques, provides a source operating in the short nanosecond or sub-nanosecond regime which is less expensive than the micro-machining sources now conventionally used, generating pulses as much as 4 orders of magnitude smaller than that in the known micromachining arts, and thus producing a greatly decreased heat affected zone which is practical for a wide variety of applications while avoiding the greatly increased cost of present femtosecond systems.
[0008] As mentioned above, Q-switching is currently a common technique for generating nanosecond optical pulses. It is known that the main parameter which determines the duration of a Q-switched laser pulse is the laser cavity round-trip time T round-trip =2L cavity /c, where c is the speed of light and L cavity is the laser cavity length. Therefore, shorter laser cavity length is generally required for generating shorter Q-switched pulses. However, it is known that this shortening of the cavity length normally reduces the mode volume which makes if more difficult to achieve suitable pulse energies. Further amplification in a solid-state amplifier is usually not a practical solution due to the very low gain characteristic of solid-state amplifiers. Moreover, pushing the energies from a short pulse microchip laser sufficient for micromachining, reduces the microchip laser efficiencies to around 5%.
[0009] Here we demonstrate that by using a low energy microchip laser in conjunction with a highly efficient large core Yb fiber amplifier these problems can be overcome and subnanosecond optical pulses can be achieved at high pulse energies.
[0010] Known Nd: based lasers, in addition to being expensive, are less efficient compared to Yb-doped fiber amplifiers. For example, Nd:YAG lasers transform the diode pump power to optical output at approximately 50% efficiency. In contrast, Yb fiber amplifiers transform laser diode pump power to optical output with about 90% efficiency. This better efficiency leads to certain cost savings, especially when the comparison is based on cost per unit of output power.
[0011] The amplification of high peak-power and high-energy pulses in a diffraction-limited optical beam in single-mode (SM) optical fiber amplifiers is generally limited by the small fiber core size that needs to be employed to ensure SM operation of the fiber. To overcome the energy and peak power limitations, recently the use of multi-mode (MM) fiber amplifiers has been suggested (U.S. Pat. No. 5,818,630 to Fermann and Harter, herein incorporated by reference). In this work the loss of spatial beam quality in MM fiber amplifiers is prevented by excitation of the fundamental mode via the use of appropriate mode-matching bulk optics or fiber tapers as suggested in U.S. Ser. No. 09/199,728 to Fermann et al., herein incorporated by reference.
[0012] Particularly interesting are MM fiber amplifiers that are double-clad since they can be conveniently pumped with high-power diode lasers to produce high average powers. Moreover, the achievable small cladding/core ratio in double-clad MM fibers also allows the efficient operation of fiber lasers with small absorption cross sections, as suggested in the aforementioned U.S. Pat. No. 5,818,630 to Fermann and Harter.
[0013] Cladding-pumped fiber amplifiers and lasers have been known for many years. See U.S. Pat. No. 4,829,529 to J. D. Kafka, U.S. Pat. No. 4,815,079 to Snitzer et al., U.S. Pat. No. 5,854,865 to Goldberg, U.S. Pat. No. 5,864,644 to DiGiovanni et al., and U.S. Pat. No. 5,867,305 to Waarts et al. In the early work in this area (Kafka and Snitzer) only double-clad fiber amplifiers comprising a SM core were considered for cladding-pumping, resulting in obvious limitations for the amplification of high peak power pulses. Moreover, Snitzer et al. only considered double clad fibers with approximately rectangular-shaped or non-centrosymmetric cladding cross sections to optimize the absorption efficiency of such fibers. The use of relatively small cladding/core area ratios enabled by double-clad fibers with a large multi-mode core, however, allows for the efficient implementation of any arbitrary cladding cross section, i.e. circular, circular with an offset core, rectangular, hexagonal, gear-shaped, octagonal etc. The work by Kafka was equally restrictive in that it only considered double-clad fibers with a single-mode core pumped with coherent pump diode lasers. Again the use of relatively small cladding/core area ratios enabled by double-clad fibers with a large multi-mode core enables the efficient implementation of pump diode lasers with any degree of coherence.
[0014] The later work of Goldberg and DiGiovanni was not necessarily restricted to the use of double-clad fibers with SM fiber cores. However, none of the work by Goldberg and DiGiovanni (or Kafka, Snitzer or Waarts et al.) considered any technique for the effective use of multi-mode double-clad fibers as diffraction-limited or near diffraction-limited high-power amplifiers. No methods were described for exciting the fundamental mode in multi-mode amplifiers, no methods were described for minimizing mode-coupling in multi-mode amplifiers and no methods were described for controlling the excitation and the size of the fundamental mode by gain-guiding or by the implementation of an optimized distribution of the dopant ions inside the multi-mode fiber core.
[0015] Moreover, the specific pump injection technique suggested by DiGiovanni comprises built-in limitations for the efficiency of fundamental-mode excitation in multi-mode fiber amplifiers. DiGiovanni considers a fused taper bundle with a single-mode fiber pig-tail in the center of the bundle, which is then spliced to the double-clad amplifier fiber to simultaneously deliver both the pump light (via the outside fibers of the fused taper bundle) and the signal light (via the single-mode fiber pig-tail) to the amplifier fiber. Due to the limited packing ability of circular structures, air gaps remain in the fiber bundle before tapering. Once tapered, surface tension pulls all the fibers in the fiber bundle together, essentially eliminating the air gaps (as discussed by DiGiovanni et al.). As a result the outside cladding of the taper bundle becomes distorted (resulting in a non-circular shape with ridges where the fibers were touching and with valleys where there were air-gaps). Hence the central core region and the fundamental mode also become distorted which limits the excitation efficiency of the fundamental mode in a MM fiber when splicing the fiber bundle to the double-clad fiber. In fact any geometric differences in the cladding shape of the fiber bundle or the double-clad fiber will lead to a limited excitation efficiency of the fundamental mode in the MM fiber in the process of splicing.
[0016] For reducing size and cost of the system as well as for increasing efficiency of the amplification side-pumping (as described in aforementioned U.S. Pat. No. 5,818,630) rather than end-pumping might be advantageous. For the benefits of fiber reliability the use of fiber couplers is preferred. The use of fiber couplers for pump light injection into MM fibers is discussed in aforementioned U.S. Ser. No. 09/199,728.
[0017] Normally for many applications a single polarization is desirable, so the use of polarization preserving fiber is desirable. There are several means of making polarization preserving fiber. However, for multimode fiber, elliptical core fiber is the easiest to manufacture and to obtain at this time.
[0018] Another attractive feature would be ease of fiber coupling the laser to the application, by using the amplifier fiber as the fiber delivery system, or a multimode undoped fiber spliced to the end of the amplifier fiber. This is similar to the fiber delivery system described in U.S. Pat. No. 5,867,304 and its progeny, herein incorporated by reference, where a multimode fiber is used for delivery of a single mode beam. The purpose is to lower the intensity in the fiber by using the larger effective mode-field diameter. This allows higher peak powers; >1 KW pulses can be transmitted without the onset of nonlinear processes. In U.S. Pat. No. 5,867,304, this fiber is used with ultrashort pulses where the fiber dispersion distorts the pulses. However, with nanosecond pulses, dispersion has a negligible effect on the pulse width so dispersion compensation is not necessary.
SUMMARY OF THE INVENTION
[0019] According to the invention, the goals set out in the foregoing are achieved through the use of a miniature Q-switched pulse source which is coupled to a doped Yb fiber laser which obtains single mode amplification in a multi mode fiber. Short pulse duration, efficiency, high power, high energy, cost efficiency and compactness are essentially achieved through the use of the combination of a compact diode-pumped microchip laser and a specially designed diode-pumped fiber amplifier. Short duration is achieved through the short cavity length of a microchip laser, whereas high efficiency is achieved through the use of a Yb-doped fiber amplifier pumped at ˜980 nm. High power is achieved through cladding pumping geometry, and large fiber core (high core to cladding ratio).
[0020] High energy is achieved through a number of design features: the large core, with single mode excitation and propagation, allows a large cross-sectional area and, consequently, permits relatively low peak intensities and high saturation energies. Further, the large core provides a good core-to-cladding ratio, which in conjunction with the high doping level available for Yb significantly reduces the pump absorption length and allows for short amplifier lengths (0.1 to ˜2 m), thus reducing detrimental nonlinear effects in the fiber without compromising power and energy extraction efficiencies. For very large cores, direct in-core pumping can be used. Side pumping provides higher power extraction efficiency and shorter interaction length compared to copropagating geometries (along with pump diode protection). Pigtailing of the fiber ends increases the surface damage threshold and allows a significant increase in output pulse energies and powers, while a composite core allows the robust coupling of the microchip seed pump into a fundamental mode of the fiber core. This also permits use of a non-perfectly-gaussian input beam from the microchip laser.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic layout of the laser system of the invention;
[0022] FIG. 2 illustrates schematically one actively Q-switched micro-laser according to the invention;
[0023] FIG. 2 a illustrates a typical layout of the actively Q-switched micro chip laser;
[0024] FIG. 3 illustrates the temporal profile of the output of the lasers of FIGS. 2 and 2 a ; and
[0025] FIGS. 4 and 4 a , where FIG. 4 is presented as an inset in FIG. 1 , illustrate a fiber-end coupling and optical damage avoidance technique.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] FIG. 1 illustrates the system configuration of the laser according to the present invention. In this Figure, reference numeral 101 indicates a microchip laser source, illustrated in greater detail in FIGS. 2 and 2 ( a ). It should be noted that, as used herein, the term “micro chip laser” refers to a laser of small device size, where at least some of the components, such as the gain medium and the end mirror, are monolithic. In this specification, the terms “microchip laser” and “microlaser” are used interchangeably to refer to a laser having these characteristics. As described in detail below, the micro chip laser 101 according to the invention is an actively Q-switched laser which is typically diode pumped.
[0027] In order to achieve excitation of only the fundamental mode in a multimode-core fiber amplifier, the beam waist ω input of a mode coupled into the amplifier from a microchip laser has to approximately match the beam waist ω mode of this fundamental mode: ω input ≈ω mode . Note, that for the step-index fiber ω mode =0.7 r core, where r core is the radius of a fiber core. Therefore, the output of the microchip laser 101 has to be directed into the fiber amplifier input ( FIG. 4 ) through properly designed mode-matching optics 102 . The essential function of this mode-matching optical arrangement is to transform the mode size of an optical beam at the output of a microchip laser ω output into the proper beam size ω input at the input of the fiber amplifier. This imaging function can be achieved by a variety of optical arrangements, one example of which is schematically represented in FIG. 1 . It is not desirable that the pump light and the signal light from the microchip laser be focussed in the same plane, and thus the mode matching optics are designed to focus only the signal light output of the microchip laser at the entry point of the fiber laser.
[0028] The inventors have determined experimentally that limitations on the maximum extractable energies in a fiber amplifier originate from a number of effects, two significant ones being the Raman gain and surface damage at the input and output facets of the fiber core.
[0029] The optical damage threshold at the surface of a glass is characterized by the optical intensity I th damage of an optical beam at this surface. Generally, this threshold intensity is determined by the type of material used and by its surface quality. It also depends on the duration of the pulse and average power (repetition rate) of the pulse train. As is known, the threshold intensity for optical damage in the nanosecond range decreases as the reciprocal of the square root of the laser temporal pulsewidth: I th damage ∝ 1/{square root}T pulse .
[0030] The inventors have demonstrated that the optical surface damage threshold can be significantly increased by using a beam expansion technique, as shown schematically in FIG. 4 and in greater detail in FIG. 4 a . Here, the fiber-end is bonded to a buffer of the same material as the fiber. At the end surface, the optical beam will be expanded to ω expanded according to:
ω expanded = ω mode ( 1 + 2 L / ω mode 2 k )
[0031] Here, k=2π/λ, n is the glass refractive index, λ is the wavelength of the amplified signal and L is the thickness of the buffer. It is critical that the quality of the bond between the surfaces of the fiber and the buffer be sufficiently high to eliminate any optical interface, and, thus, to eliminate surface damage at this surface. Various known bonding techniques can be used to achieve this quality. In the present case, a silica-glass rod of the same diameter as the outer diameter of the pump-cladding was spliced to the end of the fiber. The maximum improvement η of the damage threshold is determined by the square of the ratio between the radius of the buffer rod R buffer and the size of the core mode ω mode : η=(R bufer /ω mode ) 2 . In the case of a 50 micron core and a 300 micron buffer pigtail as used in our experimental configuration the improvement was found to be ˜70 times. Such buffer-pigtail protection is required for both input and output ends of an amplifier. In the case signal and pump beams are entering the same end of a fiber (copropagating configuration) the incoming laser beam has to be focused on the end of the fiber, as shown in FIG. 4 a , inside the bonded buffer, where there is no interface. If the bonded buffer is a coreless rod of the same diameter as fiber-amplifier inner cladding (pump cladding), as shown in FIG. 4 a , the pump beam should be focused at the entrance facet of this silica rod. Note, that generally this buffer can be a slab with transverse dimension much larger than the pump cladding. In this case pump beam could be directly focused into the pump cladding. In the case side pumping is used via a V-groove or a fiber pigtail the corresponding element can be either placed directly in the fiber amplifier after the buffer bonding point, or (if a silica rod is used as a buffer) in this coreless pigtail.
[0032] The Raman effect causes the spectrum of the amplified pulse to shift towards the longer wavelengths and outside the amplification bandwidth of the Yb-fiber amplifier. Raman effect onset is characterized by a threshold intensity I th Raman in the fiber core which, as is known in the prior art, is inversely proportional to the effective propagation length L eff of an amplified pulse and the Raman gain coefficient: I th Raman ∝ 1/L eff g Raman . Since the Raman gain coefficient is determined by the fiber glass properties, in order to maximize extractable peak powers and, hence, pulse energies, one has to increase the core size and decrease the interaction length. The interaction length can be reduced by using fibers with high doping level which lowers the fiber length, propagating amplified pulses opposite to the direction of the pump beam which lowers the pulse energy until the end of the fiber where the gain will be higher. Also, use of multimode large core fibers in the double clad configuration facilitates pump absorption and allows shorter amplifier lengths.
[0033] It is important to note that for certain applications the presence of strong Raman components in the amplified pulses does not reduce the usability of these pulses. One example is laser marking. The inventors demonstrated experimentally that surface marking is not sensitive to the Raman spectral shift and there is no degradation in the marking quality even for pulses with only a small fraction of the total energy in non-Raman shifted spectral components. In one specific example, this allowed use of ˜150 μJ of total pulse energy vs ˜40 μJ that was available without Raman shifting. Thus, for this type of application significantly higher energies are available from this particular fiber amplifier.
[0034] However, many applications are sensitive to the presence of the Raman shift. For example, when wavelength shift is required prior to end use, via second-harmonic or other frequency conversion methods, the Raman component would significantly reduce the efficiency of this conversion and would produce large amplitude fluctuations. For such applications, a number of existing techniques currently employed in fiber telecommunication systems (See, OFC'95 Tutorial Session) could be used for Raman-effect reduction in the fiber amplifiers, in addition to the methods described in this invention for optimizing fiber amplifiers in order to minimize their susceptibility to Raman effect.
[0035] The fiber amplifier 103 is a Yb-doped large-core cladding-pumped fiber amplifier. The core diameter of this fiber is approximately 10 micrometers −1 mm in diameter and thus is a true multimode fiber. However, this multimode fiber performs single mode amplification using the techniques described in U.S. Pat. No. 5,818,630, herewith incorporated by reference.
[0036] Reference numeral 104 illustrates the pump for the Yb multimode fiber laser. The pump is advantageously configured as a side-pumping broad area laser diode, the details of which are well known in the art. The Yb fiber amplifier can transform the pump power into an optical output with an extremely high efficiency of 90%. In addition, the multimode Yb amplifier fiber produces an output which is higher by more than an order of magnitude over that obtainable with a corresponding conventional single mode fiber amplifier. The combination of extremely high efficiency and high gain allows the source microchip laser to operate in a relatively low energy, higher efficiency regime with little input power.
[0037] FIGS. 2 and 2 ( a ) illustrate two preferred embodiments of the micro-laser or microchip laser used according to the invention. These devices are extremely compact, simple, inexpensive and have low power requirements, yet produce extremely short high peak power pulses. According to the invention, the microlasers employed are diode pumped lasers which are actively Q-switched. A primary advantage of these miniature lasers is that they readily provide output laser pulses of very short duration as a consequence of their short laser cavities. Active Q-switching gives good control over the repetition rate and the number of pulses delivered at a time, which is useful in marking and micromachining applications.
[0038] The microchip laser is a solid-state device designed to provide nanosecond laser pulses at 1064 nm wavelength. Diode pumping enables high pump-to-laser efficiency, compact design, and reduced thermal problems in the gain material. The cavity is designed to provide the shortest possible pulse duration achievable with active Q-switching with moderate (3 micro J) pulse energy.
[0039] Two representative laser cavity designs are shown in the Figures. The gain material is Nd doped Yttrium Orthovanadate (Nd:YVO 4 ) at 1% doping level. It is cut and oriented in a way (a-cut) to provide maximum absorption at the pump wavelength. In addition, the crystal is wedge shaped in FIG. 2 a , which allows the laser to operate only in one linear polarization. The crystal is pumped longitudinally through its coated dichroic dielectric mirror surface 201 . The pump laser 203 is a 100 micron wide laser diode with 1 Watt cw pump power. The coating 201 provides passage of pump light at 808 nm and reflection of laser light at 1064 nm. This surface acts also as a laser cavity mirror. The laser has a flat output coupler. Some thermal focusing in the cavity tends to stabilize the laser cavity mode, but it is basically an unstable resonator.
[0040] A Pockels cell 207 and a quarter-wave plate 209 inside the cavity form an electro-optic Q-switch. The Pockels cell is made of LiNbO 3 , in the transversal field configuration. The Pockels cell at the off state has zero retardation. The quarter-wave plate provides a static half wave retardation of light in a round trip, which means changing the polarization of light inside the cavity. This opposite polarization is then deflected out of the cavity ( FIG. 2 a ) by the wedge shaped gain material acting as a polarizer, or a polarizer is placed inside the cavity ( FIG. 2 ). The laser is in the static off state with the voltage off at the Pockels cell. When the gain material is pumped continuously, the pump energy is stored in the gain material for approximately 100 microseconds, the fluorescence lifetime of the gain material. To Q-switch the laser, a fast, 2.5 ns rise time high voltage pulse (1200 V) is applied to the Pockels cell. The voltage on the Pockels cell introduces a quarter-wave retardation, which compensates the retardation of the wave plate. The intra-cavity laser field then builds up unimpeded until it finally reaches saturation by depleting the gain. The laser pulse leaves the cavity through the output coupler 211 , which has 70% reflectivity and 30% transmission. The resulting laser pulse has 750 ps pulse duration and 3 micro J energy ( FIG. 3 ). A solid-state driving electronics circuit provides the fast, high voltage switching pulses for the Pockels cell with a repetition rate up to 15 kHz. To operate the laser as a cw source a static voltage can be applied to the Pockels cell.
[0041] Single longitudinal mode operation is often desired in lasers. Besides the favorable spectral properties to the laser, single-mode operation reduces the timing jitter. In single longitudinal mode operation there is no mode competition and gain cross-saturation between modes. As a result, the uncertainty of the turn-on time of the laser relative to the trigger pulse, the jitter, is reduced. Timing jitter of less than 100 ps is obtained when the laser operates in single mode.
[0042] The laser cavity is designed for single-longitudinal-mode operation. For long term stability it is particularly important that the laser cavity is stabilized against temperature induced changes. The cavity is designed so that temperature induced effects do not cause mode-hopping in the laser. The mechanical and optical construction of the laser is such that the thermal expansion of the base whereon the laser in mounted compensates for the thermal effects in the materials. In addition to thermal expansion, further consideration was given to high thermal conductivity and good electrical and mechanical properties of the base material, which enables temperature stabilization of the components.
[0043] Because the length of the resonator is approximately 8 mm, the laser can support 4 to 6 longitudinal modes at this cavity length. To achieve single mode operation we employed a resonant reflector etalon output coupler. The use of an resonant reflector etalon to maintain single mode operation is described in Koechner pp. 242-244. The output coupler is a solid Fabry-Perot etalon working in the reflection mode. Its reflectivity R is modulated as a function of wavelength. The maximum value of reflectivity occurs at the resonant wavelengths given by
δ étalon /2 π=m, (1)
where δ etalon is the phase difference between interfering optical beams in the etalon at consecutive reflections and m is a half integer number (m=½, 3/2, 5/2, . . . ).
[0044] On the other hand, resonant wavelengths of the laser cavity are determined by the total optical phase difference between beams of consecutive reflections inside the cavity, δ cav ,
δ cav =4πΣ( n i 1 i )/λ
The summation takes into account all the optical materials; gain material, Pockels cell, polarizer and quarter-waveplate material and air with their respective optical thickness n i 1 i . The resonant condition for the cavity is
δ cav /2 π=n, (2)
where n is an integer value (n=1, 2, 3, . . . ). Lasing occurs essentially when the resonant wavelength of the output coupler etalon coincides with the resonant wavelength of the laser resonator cavity. This is given by simultaneous satisfaction of the above half-integer and integer conditions for m and n respectively. The number of allowable modes under the gain profile can be restricted to 1 by proper choice of the output coupler etalon. In our embodiment of the microlaser a single uncoated LiNbO 3 plate of 1 mm thickness provides sufficient mode selectivity to allow the laser to operate in a single longitudinal mode.
[0045] The resonance conditions (1) and (2) are temperature dependent, since the thermal expansion and the thermal change of the refractive index changes the optical path-length in the laser cavity and in the resonant reflector output coupler. These effects combine to shift the resonance peaks of the resonant reflector and the laser cavity. We have a limited choice of the optical materials from which the laser is constructed. Their thermal expansion constants and thermal induced refractive index coefficients determine the thermal change of resonance conditions, which in general results in a mismatch of resonances (1) and (2) as the temperature changes and causes mode hopping of the laser. The thermal expansion of the base on which the laser is constructed also contributes to the change of the wavelength of the laser. We have a rather free choice of the base material. By using Aluminum Nitride ceramic as the laser base the thermal shift of the laser wavelength was matched to the thermal shift of the resonance condition of the resonant reflector output coupler and mode hopping has not occurred within a 4 degree C. temperature interval. Temperature stabilization of the laser cavity within 1 degree C. resulted in continuous single longitudinal mode operation of the laser.
[0046] An alternative source may be a passively Q-switched microchip laser, which can be very inexpensive and may be preferred in some cases for this reason. The primary reason to use a miniature source is to keep the laser cavity short which reduces the pulse width of the laser.
[0047] The miniature laser is coupled to a doped fiber gain medium. In the invention this medium is a Yb:fiber.
[0048] In order to reach higher peak powers, the invention utilizes a multi-mode fiber to propagate single mode pulses as described in U.S. Pat. No. 5,818,630. As described above a mode converter is used to convert the single mode input to excite the fundamental mode of the multimode fiber. The mode converter 102 used in this case is a combination of lenses which mode-matches the output of the microchip laser to the beam diameter for single mode excitation of the multimode fiber. In addition to the lenses for mode-conversion, gain guiding in the Yb:fiber can be used to relax the tolerances on mode matching. Without gain in the Yb fiber, robust fundamental-mode excitation becomes increasingly difficult to achieve for the increasing core size of a fiber amplifier. We found experimentally that it is particularly advantageous to employ specially designed fibers in which Yb-doping in the center of the core has a significantly smaller diameter than the core itself. In this case, the fundamental mode light experiences significantly higher gain than multimode light. In our experimental configuration, we used 50 μm diameter core with 25 μm diameter doped region in the center, which exhibited a significantly more robust performance compared to 25 μm homogeneously doped core. Besides relaxing the alignment tolerances, the beam parameters of the source are also relaxed. As the microchip laser may not have a perfect diffraction limited beam output, gain guiding can be used to correct for this. Also, gain guiding can correct the distortion expected from DiGiovanni pump couplers.
[0049] The Yb fiber in this example had a 300 μm outer diameter and a 50 μm core. The use of relatively small cladding/core area ratios enabled by double-clad fibers, together with a large multi-mode core, allows for the efficient absorption of the pump with, for example, a gear-shape cladding cross section. The resultant Yb amplifier can be as short as 1.5 M long, as compared to 5-40 M which would be required of a typical single mode Yb amplifier.
[0050] Another advantage of this optical source is the ease of adding a multimode fiber delivery system which propagates a single-mode. In many applications fiber delivery is very important, such as in surgery, dentistry and marking in confined spaces. An example of marking in confined spaces is the marking of assembled automotive or other parts for antitheft purposes.
[0051] An additional advantage of the shorter pulse is that nonlinear processes for frequency conversion are more efficient with the higher peak powers which come from shorter pulses with similar energies. For certain applications where wavelength conversion is necessary, for example in UV-range radiation for via hole drilling, the output of the laser must be frequency tripled to create the UV radiation. This source, could, for example, replace frequency tripled Q-switched Nd:YAG lasers and eximer lasers for this application.
[0052] Another application where frequency conversion is important is dentistry. For example, in U.S. Pat. No. 5,720,894, it is described that UV radiation performs relatively damage free material removal by hard tissue ablation primarily due to the stronger absorption of that wavelength regime. Three preferred wavelengths for applications in medicine and dentistry are 2.1 μm, 2.9 μm and 1.55 μm. Like UV radiation, the preference is due to the strong absorption coefficient of biological tissues at these wavelengths.
[0053] The most straight forward means for generating 1.55 μm radiation is to use a laser source which emits at 1.55 μm and a doped fiber which amplifies 1.55 μm radiation. A microchip laser which emits 1.55 μm radiation is known, and described in Thony et al. It is well known that erbium fiber amplifies 1.5 μm radiation. An alternative source could be a compact erbium doped waveguide laser as described in; H. Suche, T. Oesselke, J. Pandavenes, R. Ricken, K. Rochhausen, W. Sohler, S. Balsamo, I. Montrosset, and K. K. Wong “Efficient Q-switched Ti;Er:LiNbO 3 waveguide laser”, Electron. Lett., Vol. 34, No. 12, 11 Jun. 1998, pp 1228-1230.
[0054] Another alternative is to use a laser source which emits a different wavelength, such as that of the invention, and use a frequency conversion step to generate the 1.5 μm radiation. Examples of a nonlinear conversion step at the output include doubling, tripling, quadrupling, Raman shift, OPO, OPA or OPG. To generate 1.55 μm radiation, converting a 1.06 source in a PPLN OPG is quite convenient.
[0055] In order to generate other wavelengths such as 2.1 and 2.9 μm similar methods can be applied to this laser concept.
[0056] The multimode amplifier of the invention can also amplify a cw source or operate as a cw source. For example, a marking laser often has the option of being operated in a cw mode for generating more of a heat type mark. For the design of high-power cw lasers the use of MM fibers is advantageous as the reduced cladding/core area ratio reduces the absorption length in such structures. For very high cw laser powers, nonlinear effects can indeed occur and thus MM fibers can be used for the construction of compact ultra-high power cw fiber lasers. The MM fibers can then be effectively used for the pumping of fiber Raman amplifiers or for the construction of Raman lasers operating at wavelength regions shifted away from the gain band of the doped fibers.
[0057] As previously indicated, a number of major advantages are achieved according to the invention by employing the combination of a Q-switched microchip laser and a Yb: fiber amplifier. Because of the efficiency and gain of the Yb fiber amplifier, the output power of the microchip laser need not be large. The peak power of this amplifier is limited by nonlinear effects in the fiber and by the optical damage thresholds primarily at the fiber ends. The delivery fiber may be a simple multimode undoped fiber spliced to the end of the amplifier fiber, or the amplifier 103 can itself constitute the fiber delivery system. Thus, a simple, inexpensive laser system suitable for a wide variety of applications can be efficiently produced. | The invention describes techniques for the control of the spatial as well as spectral beam quality of multi-mode fiber amplification of high peak power pulses as well as using such a configuration to replace the present diode-pumped, Neodynium based sources. Perfect spatial beam-quality can be ensured by exciting the fundamental mode in the multi-mode fibers with appropriate mode-matching optics and techniques. The loss of spatial beam-quality in the multi-mode fibers along the fiber length can be minimized by using multi-mode fibers with large cladding diameters. Near diffraction-limited coherent multi-mode amplifiers can be conveniently cladding pumped, allowing for the generation of high average power. Moreover, the polarization state in the multi-mode fiber amplifiers can be preserved by implementing multi-mode fibers with stress producing regions or elliptical fiber cores These lasers find application as a general replacement of Nd: based lasers, especially Nd:YAG lasers. Particularly utility is disclosed for applications in the marking, micro-machining and drilling areas. | 7 |
FIELD OF THE INVENTION
[0001] The present invention refers to a sustainable method for increasing the recovery of petroleum from petroleum-bearing subterranean formations, particularly formations wherein petroleum is found as oil which is too viscous to flow or be pumped.
[0002] More particularly the present invention refers to a method of recovery (extraction) of petroleum from the original geological formation utilising injection of diesel and/or biodiesel oil through the injection well, reducing the viscosity of the petroleum, dissolving heavier and immobile petroleum fractions and traversing the reservoir acting through the sweeping and displacement effectiveness, increasing oil recovery and the proven reserve.
BACKGROUND OF THE INVENTION
[0003] In view of the increasing need for energy one of the great challenges of the petroleum industry worldwide is achieving maintenance of production to satisfy current demands.
[0004] The model currently followed aims to maintain production and reserves through the discovery of new accumulations; although such approach has in general led to the discovery of new offshore accumulations, they are frequently found at great depths in increasingly-deep water and frequently in deposits wherein the oil found is of high viscosity.
[0005] The association of viscous oil, great depths and maritime environment results in enormous technico-operational complexity and high production costs and said scenario affects technical and economic effectiveness and production sustainability.
[0006] Environmental sustainability under such conditions is also a critical matter, principally with reference to the collection and disposal of fluids.
[0007] Thus the great challenges for the petroleum industry in Brazil and worldwide are maintenance of production, to maintain self-sufficiency, and replacement of reserves, to ensure sustainable future supply, being understood as socio-environmentally responsible.
[0008] Furthermore in various parts of the world diverse petroleum-bearing geological formations are found wherein only conventional methods of petroleum recovery are used, however others cannot be fully exploited using such methods because the oil contained in such formations is too viscous to flow or be pumped.
[0009] As a consequence thereof another important aspect of the current model is the fact of large investments being made in prospection in the search for new reserves without appropriately exhausting those already being worked and still containing a large volume of remaining oil, signifying the disrespectful extraction of a natural resource without concern for future generations.
[0010] Therefore increasing the working life of a field is directly related with the currently-available techniques of Enhanced Petroleum Recovery (EPR), the methods hitherto employed solely taking into consideration immediate technical and economic effectiveness without great attention being paid to socio-environmental aspects.
[0011] According to the literature there exists a series of chemical additives having the objective of viscosity reduction and of relatively-restricted application, normally employed as a method of stimulation in production wells to eliminate formation damage or as an additive in cyclic steam-injection processes (injection/production in production wells). In a broader sense such products do not satisfy technical, economic and environmental requirements in the manner herein proposed by the present invention.
RELATED ART
[0012] The use of solvents is already known and widely employed for the dilution of viscous oils, the objective whereof being to facilitate transport within wells or in production lines or even volumetric oil transfer.
[0013] The use of solvents in petroleum production has been restricted to or concentrated in countries wherein geological formations are found having ultraviscous oils and very low ambient temperatures, such as Venezuela and Canada, in the form of well stimulation, injection/production through the production well.
[0014] In general the currently-existing technology having this objective has been solely concerned with the technical and economic effectiveness of the processes employed and thus the solvents employed heretofore cause environmental disequilibrium, both on the surface, having consequences for the ecosystem and mankind, and within the environment of the geological reservoir, causing chemical, physical, physico-chemical and biological disequilibrium in said environment.
[0015] Utilisation of substances classified as environmentally-damaging in the diverse methods hereunto known has shown that said substances were selected taking into consideration solely availability and cost to the detriment of environmental matters, which substances have thus become the target of increasing questioning by environmental entities in various parts of the world, reflecting a new philosophy in society.
[0016] U.S. Pat. No. 6,279,653 discloses that the viscosity of heavy oils may be significantly reduced converting such oil into a stable microemulsion. Such microemulsion is formed combining alkaline reagents with the oil and subjecting the same to ultrasonic energy. Said reduction in oil viscosity permits the oil to be pumped out of the well and it may then be conveyed for refining, however introducing extraneous substances into the environment of the geological formation, which same require to be removed from such oil through particular procedures, in addition to the utilisation of ultrasound.
[0017] U.S. Pat. No. 5,025,863 discloses a process for well stimulation (injection/production in the production well) wherein a slug of immiscible natural gas is injected into a formation through the production well. The well is then shut in for a given time (‘soak period’) for the gas to enter solution. The well is then put into production when petroleum is then produced together with the gas utilising conventional production equipment and techniques, however the fact of struggling with gas and injecting the same through the production well raises other questions in terms of safety and effectiveness of the procedure.
[0018] U.S. Pat. No. 6,491,053 refers to a known manner of reducing the viscosity of heavy petroleum through admixing the same with a liquid component of lower density. Said component may be petrol, kerosene or other components such as to better pump the oil. At its destination the solvent added may be removed and recycled. This procedure is expensive and when crude petroleum requires pumping over long distances recirculation of the viscosity-reducing agent becomes complicated. This is a process to ensure flushing pipelines and lines, it is not a method for recovering petroleum which acts within the reservoir.
[0019] U.S. Pat. No. 4,531,586 also discloses a process for cyclic stimulation of heavy oil production in a petroleum reservoir comprising injection (through the production well) into the reservoir of a liquid solvent such as diesel oil or a light petroleum and production of the oil/solvent admixture. This is a method of well stimulation, injection and production in the production well having a reduced scope, not being an enhanced petroleum recovery method.
[0020] U.S. Pat. No. 3,127,934 refers to the injection of two slugs of solvents through the injection well. The first slug comprises solvents of low molecular weight, specifically gases (C1 to C4) which as the author discloses dissolve the oil contacted effectively, however it has a great tendency to pass around the regions bearing oil creating preferential channels, that is to say the gases tend to seek regions of high permeability. The second slug comprises solvents or other types of material which, in contact with water, polymerise forming a product blocking the region washed. This is a different concept, involving plugging regions of high permeability. In both cases referred to the use of gases involves very delicate situations in terms of operational and safety matters, and as to the materials which polymerise, these may also prevent some areas of interest in the formation being prevented from subjection to more efficient washing.
[0021] Once the natural energy of a reservoir has been exhausted it is normal to commence secondary recovery, that is to say injection of water or gas as displacing fluids. The effectiveness of the process is low because such fluids have a tendency to create preferential channels in regions or beds of high permeability.
[0022] The degree of formation of such preferential channels is determined by several factors of which the most important is the ratio between viscosity of the petroleum to be recovered and viscosity of the fluid injected.
[0023] A manner of minimising formation of such preferential channels is to seek to more closely approximate the viscosities of the ‘displacing’ and ‘displaced’ (petroleum) fluids. One option is the addition of polymeric additives to injection water (displacing phase) to increase the viscosity thereof. The second option is to reduce the viscosity of the petroleum through the use of miscible fluids.
[0024] In many cases wherein the oil is of high viscosity the process of secondary recovery ends by being abandoned because the oil can no longer be economically produced due to the high ratios of water injection to oil produced.
[0025] When working with an oil of high viscosity, should the expected water injectivity into the reservoir not be achieved, the normal practice is injection of steam into the formation with the objective of improving the extraction flow of the oil, acting in a general manner on the production well which, in a petroleum context, represents stimulation of the production well.
[0026] In general approximately 30% of the petroleum is recovered through conventional Primary and Secondary recovery processes. Thus 70% of all the original petroleum still remains in reservoirs and this is therefore the target of Tertiary Recovery, also known as Enhanced Petroleum Recovery (EPR).
[0027] Such cost-effectiveness is however a function of the effectiveness of recovery techniques, investment wherein has been put aside due to investment in new discoveries. Investment in such techniques signifies extending the working life of a field and recovering in a respectful manner a non-renewable natural resource.
[0028] Thus in spite of advances in the art there still exists a requirement for an Enhanced Petroleum Recovery process, either for normal exploitation or even for better utilisation of the oil contained in a geological formation, thus increasing the working life of a reservoir.
SUMMARY OF THE INVENTION
[0029] The present invention presents a method of Enhanced Petroleum Recovery combining general, economic, environmental and social effectiveness in order to increase the recovery factor of onshore or offshore fields, more precisely through the use of a miscible substance for use in reservoirs, having the objective of reducing viscosity and fluidifying the petroleum. Such substance is selected from the group consisting of diesel oil or fractionated gas oil from petroleum, or even biodiesel, being similar and derived from plants, or light oil, which products may be utilised pure or with additives, in an isolated manner or together with other fluids or methods such as: steam, polymers, etc. Such substances, subject of the present patent, require to be highly-miscible with the oil contained in the geological formation wherein it is intended to act, injection being executed through the injection well and traversing the entire reservoir to the production well, which in the petroleum context represents Enhanced Petroleum Recovery (EPR).
[0030] For the purposes of the present invention solvent is understood to be biodiesel or oil, having characteristics similar to the diesel habitually produced from mineral sources, being produced however from renewable sources, normally agricultural sources.
[0031] More specifically the present invention refers to the use of solvents such as light liquid petroleum fractions, for example diesel oil or gas oil, a light petroleum, and essential oils derived from renewable sources such as, for example, biodiesel, used in a pure form or in a common admixture in any proportion for injection into a geological formation through the injection well, resulting in a final admixture (petroleum/injected solvent) having a much lower viscosity and much greater fluidity than that of the original petroleum, impacting on the entire petroleum production chain. The present invention presents a real advantage in all phases of the production chain:
1) increase in recovery factor; 2) increase in proven reserves; 3) reduction in loss in lifting and transport; 4) elimination of the necessity for using additives to render paraffinic oil viable; 5) adjustment of oil viscosity to refining conditions plus, in the case of solvents derived from petroleum, their recovery and it being possible to return them to the process or be marketed.
[0037] The method of the present invention is especially indicated for utilisation when petroleum is of high viscosity or paraffinic and/or the formation is of low permeability, resulting in conditions wherein the petroleum possesses low fluidity characteristics throughout the formation.
[0038] Thus the use of diesel and/or biodiesel and the other products recommended in the present invention is indicated for petroleums of the paraffinic type, being the case of some occurrences of petroleum of the paraffinic type in Brazilian territory, or even for petroleums in low-temperature environments or which require to be transported under the rigours of such environments.
[0039] The present invention may also be employed for the displacement of immovable reserves of petroleums of the asphaltenic type wherein a small addition of aromatics to the diesel extraction charge greatly enhances the positive results with said technique.
[0040] In this context such diesel and/or biodiesel is not to be considered primordially as a solvent fluid but should be interpreted as being a fluid whose utilisation is indicated clue to it being miscible with the petroleum found in the reservoir, and not be considered as a substance extraneous to the environment wherein it is applied, in addition to also satisfying other requisites of a technical, environmental and economic nature, as aforestated.
[0041] An objective of the present invention is to provide a sustainable method of recovery by means of which significant quantities of oil may be extracted from a reservoir bearing petroleum of low fluidity through reduction in viscosity of said viscous oil with the objective of improving flow within the reservoir and pumping conditions.
[0042] Another objective of the present invention is to provide an improved process by means of which additional quantities of oil may still be recovered from reservoirs containing oil of low fluidity, principally those reservoirs which have already been normally treated by water and/or steam flooding and which in many cases would now be considered as being exhausted, wherein the procedure occurs by means of injecting into such geological formation, containing said petroleum of low fluidity, the miscible fluid referred to, such recovery being realised without requiring injection of excessive quantities of fluid miscible with the petroleum within the reservoir and which same is pushed throughout the extent of the reservoir by means of a displacing fluid such as, for example, water.
[0043] A further objective of the present invention is to provide a process of recovery by means of which an oil of low fluidity may be recovered from geological formations in a shorter time through the injection of smaller quantities of fluid and in more favourable ratios of oil to injected fluid than are possible through application of presently-known processes.
[0044] By virtue of diesel being homogeneously miscible with petroleum and both the diesel and the petroleum/diesel solution possessing relatively low densities and viscosities, flow throughout the formation is thus stimulated and the process of the present invention renders recovery possible in locations heretofore considered difficult and inefficient or even costly or impossible.
[0045] A yet further relevant aspect of the method of the present invention is that the fluid miscible with the oil contained in the formation rather than being injected through the production well is injected into the geological formation through the injection well resulting in the solvent traversing the formation from the injection well to the production well and, as a function of the difference in viscosity between the miscible fluid, lying in the intermediate band between water and the oil, it acts in a decisive manner on the effectiveness of displacement through the reduction in viscosity and dissolution of the heavier fractions of the oil impregnated in the formation and on the sweeping effectiveness.
[0046] Enhanced Petroleum Recovery, together with Secondary Recovery, always presuppose an injected (displacing) phase with the objective of displacement of the oil.
[0047] In this manner the method of the present invention has a yet further consequence of its mechanism of acting, being a significant improvement in displacement effectiveness and sweeping effectiveness within the geological petroleum-bearing formation, being the two key points of attack of the methods of Enhanced Petroleum Recovery.
[0048] Thus the final recovery factor is a function of the effectiveness of the displacing phase, being:
(i) Sweeping Effectiveness, associated with viscous forces or the difference in viscosity between the displacing/displaced (petroleum) phases; and (ii) Displacement Effectiveness, associated with the effectiveness of driving or displacement of the oil from the swept area, combined with capillary forces.
[0051] Such characteristics are of operational importance insofar as their acting conjointly contributes to more homogeneous distribution of capillarity, preventing preferential routes through the subject formation, in addition to preventing separation along the route traversed by the drive fluid.
[0052] A further important aspect is that the method of the present invention may be applied employing the same devices and equipment utilised for secondary recovery, injection of water and/or steam, at the pressure and the temperatures of the environment of the geological formation to be treated.
BRIEF DESCRIPTION OF THE FIGURES
[0053] FIG. 1 presents a table referring to the survey of technical, economic and environmental data of a number of viscosity reducers available in the Brazilian market.
[0054] FIG. 2 presents a graph showing the reduction in viscosity following utilisation of a number of substances utilised as viscosity-reducing agents.
DETAILED DESCRIPTION OF THE INVENTION
[0055] The present invention refers to the injection of liquid petroleum fractions, the classification of such petroleum fractions according with the number of carbons in the chain, as shown in Table I below.
[0000] TABLE I REFINERY PRODUCT HYDROCARBON BAND Gas C 1 -C 4 Petrol C 5 -C 10 Kerosene C 11 -C 18 Diesel C 14 -C 18 Heavy gas oil C 12 -C 25 Lubricating oil C 20 -C 40 Residue >C 40
Within this phase we emphasise the band of hydrocarbons from C 14 -C 18 corresponding to diesel being that presenting the most suitable technical and environmental effectiveness. The liquid fractions (C 5 -C 13 ) prior to those of diesel (C 14 -C 18 ) also offer technical effectiveness, however as the number of carbons in the chain decreases vapour pressure increases and, flowing therefrom, environmental risks also increase. In addition, in the liquid fraction having a number of carbons exceeding fourteen (>C 14 ), as the number of carbons in the chain increases, always being linear, environmental effectiveness increases and technical effectiveness diminishes. For application in heavier oils, generally containing significant levels of asphaltenes, a small fraction of an aromatic solvent such as xylene or toluene should be admixed with the viscosity reducers subject of this patent to prevent precipitation of asphaltenes.
[0056] Injection of gas to increase the recovery yield of oils of high viscosity is already known, being classified as conventional recovery.
[0057] In accordance with the Table presented in FIG. 1 and taking into consideration the objective of working in a sustainable manner, that is to say prioritising social and environmental responsibility, the first criterion for the evaluation of viscosity reducers has been that of the least environmental impact which they might cause.
[0058] In this manner in this initial selection all those which presented a high negative environmental impact were rejected, even in detriment to their technical advantages. Among the same there were also eliminated naphtha, C5 + , petrol, and the aromatic extract.
[0059] Also in conformity with the Table shown in FIG. 1 , diesel oil, a light petroleum represented here by oil from a specific well (Petrobrás, Brazil), turpentine and kerosene presented the least negative environmental impact, that is to say less toxicity, less danger, less risk of explosion than the other solvents due to having lower vapour pressures than the others.
[0060] In the specific case of the aromatic extract and similar products, in spite of not having a high vapour pressure like the others referred to, they present a high degree of toxicity due to their carcinogenic and mutagenic characteristics.
[0061] From among the viscosity reducers approved, those having least economic cost were diesel oil and analysed light oil proceeding from said well (Petrobrás, Brazil). The interpretation of this analysis is consolidated in the Table presented in FIG. 1 .
[0062] In a second stage the products selected, that is to say diesel oil and the light oil because they presented least environmental impact and least cost, were evaluated in accordance with their rheological performance, viscosity reduction, based on admixtures having diverse proportions of the solvent and the viscous oil from the Nativo Oeste field (Petrobrás, Brazil), on which were executed measurements of dynamic viscosity. Said analyses were compared with others executed on the same oil and other solvents under the same conditions, confirming the technical potential of said selected viscosity reducers. The results are shown in graph form in FIG. 2 .
[0063] Thus diesel oil and the light oil were approved in the environmental, technical and economic context as viscosity-reducing agents, however diesel oil was found to be best in terms of the viscosity drop obtained as a function of the proportion of petroleum.
[0064] Thus far the products were analysed and approved in an isolated manner, that is to say merely as viscosity-reducing agents. A further application for such substances was considered taking as a basis not solely their viscosity-reducing power but, in addition, the interaction thereof with the formation and their mechanism of action as a method of Enhanced Petroleum Recovery.
[0065] For operational purposes with reference to facilitating pumping conditions for lifting and transporting in pipelines the oil produced, this latter should possess a viscosity lower than 300 cP, preferably lower than 250 cP, more preferably lower than 200 cP.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0066] The understanding of Enhanced Petroleum Recovery (EPR) takes into consideration the concept of Secondary Recovery. The injection of water or gas (displacing fluids during Secondary Recovery) has as its purpose displacement of the (displaced) oil in the reservoir by means of purely-mechanical behaviour, that is to say on injecting water or on subjecting the reservoir to a process of immiscible gas injection it is not expected that there will be chemical or thermodynamic interaction of such fluids with the oil or with the rock. The fluid injected displaces the oil, occupying the pores vacated by the oil as the latter is expelled from the formation, however not the entire volume swept by the displacing fluid expels the oil. Such oil remaining in the regions invaded by the fluid injected is denominated residual and is a consequence of the effect of capillarity.
[0067] EPR and Secondary Recovery always presuppose an injected (displacing) phase having the objective of displacing the oil. The final recovery factor is a function of two aspects of effectiveness of such displacing phase: Sweeping Effectiveness, linked to viscous forces or the water/oil viscosity difference; and Displacement Effectiveness, linked to the effectiveness of driving the oil from the swept area, associated with capillary forces. Said two aspects define the points of attack of Enhanced Petroleum Recovery causing modifications to the physico-chemical and thermodynamic nature of the fluids and interactions between the same and the formation.
[0068] In order to act on Sweeping Effectiveness we require to increase the viscosity of the displacing phase or reduce the viscosity of the displaced phase (petroleum) and to affect the Displacement Effectiveness it is necessary to act on the interfacial tension between the displacing and displaced fluids and/or the wettability of the fluids/rock system.
[0069] The novel concept herein presented proposes a method of Enhanced Petroleum Recovery based on the injection of a slug of diesel oil through the injection well of the formation followed by injection of water.
[0070] Such novel concept offers technical, economic, environmental and social contributions.
[0000] 1) Technical: The mechanism of acting of the method is divided into two phases: the first during displacement of the slug of diesel oil through the formation and the second during the recommencement of water injection.
1.1) During displacement of said slug of diesel oil: the slug injected enters the formation in the regions of least resistance and reduces the viscosity of the petroleum contacted becoming incorporated into said slug of diesel oil, its viscosity increasing in proportion to the original quantities and viscosities of the components of the admixture (diesel oil and petroleum). This is the mechanism of acting on the Displacement Effectiveness of the method, that is to say solubilisation of the immovable oil, i.e. oil which would remain in the formation even following contact with injected water, rendering it mobile with consequent reduction in viscosity of such mobile oil. 1.2) During recommencement of water injection: the water front enters the formation contacting and displacing the oily phase (now petroleum/diesel oil) of lower viscosity than the previous phase (original petroleum). Said viscosity reduction of the displaced phase is translated into an increase in the Sweeping Effectiveness of the displacing phase due to reduction in the difference in viscosity between the displacing (water) and displaced (admixture) phases. 1.3) Additionally a wettability reversal (rock/oil to rock/water) may occur promoting even further displacement of the remaining oil by water injected subsequent to passage of the slug of diesel.
2) Environmental:
[0074] Upstream: Injection of the slug of diesel oil may be executed using the same water injection system already installed, however such system requires adaptation and certification in accordance with the Safety, Environment and Health (SEH) regulations and standards for handling inflammable substances.
In the formation: The method herein presented will not cause biochemical disequilibrium in a reservoir because from the chemical point of view said oil already forms part of the composition of the petroleum therefore the injection of diesel oil into a formation does not introduce substances extraneous to such formation. In the same manner disequilibrium will not arise in the biota of the formation given that the microorganisms existing therein are already adapted to this component, being one of the fractions of petroleum.
Downstream: As the product (viscosity reducer) used in this novel concept is an integral part of the petroleum and will be produced together therewith, the care required in this phase is identical to that already implemented for the petroleum.
3) Economic: As the diesel oil is a subproduct of the petroleum it has a cost being dependent on the price of petroleum and the processing for its obtainment therefrom. However, introduction of a mixture having approximately 20% diesel already significantly reduces the viscosity of the original petroleum to less than 300 cP, being sufficient to change an immovable into a movable oil. More precisely, in this case each barrel of diesel oil recovers four of petroleum and, in addition, the diesel oil extracted admixed with the petroleum may return to the process following normal processing of the recovered oil.
[0075] An economic alternative to the process wherein the price of diesel is not linked to the price of petroleum is the use of biodiesel rather than utilisation of diesel oil from petroleum. In this case a renewable source of energy would be being used for the extraction of a non-renewable natural resource, being attractive in terms of economic support for diverse agricultural regions in the world.
[0076] As well as diesel and/or biodiesel, gas oil or a light petroleum may be used.
[0077] The use of crude petroleum does not involve refining costs however it does not offer the same results in reduction of viscosity when compared with diesel.
[0078] Gas oil offers as an economic advantage over diesel one less process being hydrotreatment, thus the cost should be slightly less than that of diesel, however it also presents disadvantages in matters relating to Safety, Environment and Health (SEH).
[0000] 4) Social: The great challenges for the petroleum industry in Brazil and worldwide are maintenance of production to maintain self-sufficiency and replacement of reserves to ensure future supply with sustainability, that is to say environmental and social responsibility. Currently, to satisfy such demand companies are investing massively in new reserves exploration and particularly in Brazil the majority thereof are found in environments at great depth on the continental platform wherein the majority are constituted by heavy oils. Thus, as a consequence of the application of said operational strategy, a large quantity of oil, approximately 70% or more in onshore formations having all the support structure and in the majority of cases containing a light oil of excellent quality, now no longer require to be ‘abandoned’ due to a matter of economics, by virtue that the utilisation of the technique of the present invention greatly increases the possibilities of recovery, extending the working life of a formation, extracting natural assets in a respectful manner, taking into account the concern for future generations.
[0079] In this manner the addition of diesel oil and/or biodiesel provides the following economic advantages:
it renders the extraction of heavy or ultraviscous oil possible or feasible; it increases the recovery factor reducing residual saturation.
[0082] it contributes to the transport of petroleum in the lifting phase and flushing in pipelines in a general manner, principally in low-temperature environments;
it increases the value of petroleum through viscosity reduction and raises its API grade, rendering such oil more suitable for marketing; it adjusts the petroleum for the most favourable refining conditions; the diesel and/or biodiesel injected is not lost, it is produced admixed with the oil and may be recovered during processing and be recycled once again into the flow to be injected through the injection well for continuation of the recovery process of high-viscosity petroleum.
[0086] In this manner the present invention is a method of Enhanced Petroleum Recovery combining technical, economic, environmental and social effectiveness to increase the recovery factor of onshore or offshore fields having a high level of exploitation, more precisely the use of solvent, diesel oil, biodiesel and other similar products, used separately or in conjunction with other fluids or methods such as steam, polymers, etc, its acting mechanism being improvement in Displacement Effectiveness and Sweeping Effectiveness, the two key points of attack of Enhanced Petroleum Recovery (EPR) methods.
[0087] In addition, application of the method of the invention permits rendering high-viscosity petroleum suitable for the operational conditions of lifting and transport by virtue of ensuring flushing in production wells, lines and pipelines.
EXAMPLE
[0088] The example provided below presents a specific application of the invention to an oil produced in Brazil; due to the high-viscosity characteristics of the type of Brazilian paraffinic petroleum denominated Nativo Oeste (API-13, viscosity 3500 cP) the present invention was applied utilising a number of more-available substances having been tested with the objective of use as viscosity-reducing additives in the injection operation through injection wells in production activities.
[0089] The application of the present invention in the rheology determination tests with the objective of selecting a more appropriate viscosity reducer for use in the field to render viable steam injection into a formation through the injection well, led to the graph-shown in FIG. 2 .
[0090] In accordance with FIG. 2 , diesel achieves the result of lowering viscosity from 3500 cP to less than 250 cP at concentrations of solely 15-20%, placing it in an advantageous position with respect to the other reducers analysed, taking into account the technical, economic and environmental parameters considered for the diverse solvents available in the Brazilian market.
[0091] More precisely we observe that for each barrel of diesel injected to treat said high-viscosity oil there exists the possibility of recovering approximately five barrels of petroleum from the reservoir due to the fact of injection of diesel oil achieving a reduction in the viscosity of the oil contained in the formation to approximately 250-300 cP.
[0092] In addition the diesel oil extracted admixed with said petroleum may be returned to the injection process following normal processing of the oil recovered by extraction.
[0093] The Table shown in FIG. 1 shows the results with reference to the technical, economic and environmental data of the various solvents existing in the Brazilian market, taking into account the parameters relating to their Safety, Environment and Health (SEH) aspects.
[0094] Although the present invention has been presented in its preferred method of embodiment together with a specific example, it shall be understood that the same are merely provided illustratively and shall not be considered as limiting the spirit and scope of the present invention.
[0095] Those skilled in the art will be capable of determining the most economically-favourable percentages of utilisation for application, based on the guidance herein presented, which shall be incorporated within the spirit and scope of the present invention.
[0096] In this manner modifications to the bands of application of diesel oil and/or biodiesel which may be made over and above those herein presented will be obvious to those skilled in the art. Such modifications shall be the subject of experimentation to bring about percentage increases in the desired recovery of high-viscosity petroleum, providing benefits from the technical and economic point of view in accordance with their nature and industrial purpose. However it is clear that such modifications are incorporated within the spirit and scope of the present invention. | The present invention comprises a method of Enhanced Petroleum Recovery (EPR) combining technical, economic, environmental and social effectiveness to increase the recovery factor of onshore or offshore fields having a high degree of exploitation, more precisely through the use of a substance miscible with the diverse types of petroleum of low fluidity found in various regions. More specifically, the present invention refers to the use of solvents such as light liquid fractions of petroleum, for example diesel oil and gas oil, a light petroleum, and the essential oils derived from renewable sources such as for example biodiesel, used pure or mutually admixed in any proportion, for injection into a geological formation through an injection well, there resulting a final mixture (petroleum/injected solvent) presenting much lower viscosity and much greater fluidity than the original petroleum, having an impact throughout the petroleum production chain. The present patent presents real gains in all phases of the production chain.
For the purposes of the present invention biodiesel is understood to be oil having characteristics similar to diesel produced from mineral sources, however having been produced from renewable sources, usually agricultural sources. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for prompting the performance of cardio pulmonary resuscitation (CPR).
In this specification, CPR comprises the performance of expired air resuscitation (EAR) concurrently with external cardiac compression (ECC) in accordance with the specifications laid down by the Australian Resuscitation Council.
EAR is used on persons suffering from respiratory arrest, the essential signs of which are unconsciousness and absent respiration. On the other hand, ECC is used on persons suffering from cardiac arrest, the essential signs of which are unconsciousness, absent pulse and absent respiration.
The performance of EAR involves the following steps:
the rescuer pinching the casualty's nostrils between finger and thumb of the hand, and extending the head of the casualty to maintain the airway open;
the rescuer opening his/her mouth wide and taking a deep breath;
the rescuer placing his/her mouth firmly over the casualty's mouth making an air tight seal;
breathing firmly into the casualty's mouth, watching to see that the chest rises;
the rescuer removing his/her mouth, watching to see the chest of the casualty fall and listening for the breath exhaling;
continuing rhythmically the breathing and watching procedure in accordance with a prescribed rate dependent upon the age of the casualty.
The performance of ECC involves the following steps:
placing the casualty on his back on a firm surface;
kneeling beside the casualty's chest at right angles to the line of his body;
locating the lower half of the sternum of the casualty;
the rescuer placing the heel of one hand at this point, keeping the palm and fingers raised from the chest;
covering this hand with the heel of the other hand;
the rescuer keeping his/her arm straight, rocking forward over the casualty until the rescuer's shoulders are vertically above their hands;
pressing briskly down to depress the sternum about five centimeters;
rocking backwards releasing the pressure from the sternum;
continuing rhythmically with the aforementioned depression and release of the sternum at a prescribed rate dependent upon the age of the casualty.
In the case of cardiac arrest, it is necessary to use a combination of EAR and ECC, i.e. CPR. The performance of CPR varies depending upon whether one rescuer or two rescuers are available, whereby in the case of two rescuers one may perform EAR and the other ECC contemporaneously. In the case of there being only one rescuer, it is necessary for the one person to perform both EAR and ECC.
In practice, upon encountering a person who has suffered respiratory or cardiac arrest, the first symptom which can be readily ascertained is whether the person is unconscious or not. In accordance with the specifications set down by the Australian Resuscitation Council, at this stage the air way of the unconscious person should be cleared and opened to ensure that the person can breath.
The next obvious symptom which can be ascertained at this stage is whether the casualty is breathing or not. Accordingly, after the air way is cleared and opened, the casualty must be checked to determine whether they are breathing or not. In the event that they are not breathing, the rescuer must immediately enter into EAR technique, providing five inflations as rapidly as possible since time is vital at this stage.
After this, the characterising symptom for cardiac arrest can be checked, i.e. whether the pulse of the casualty is present or not, to ascertain whether the casualty is suffering from respiratory or cardiac arrest.
If the pulse is present, it can be ascertained that the casualty is suffering from respiratory arrest only and accordingly EAR procedure may be continued at the rate of twelve inflations per minute for an adult casualty and at the rate of twenty inflations per minute for a child or baby casualty.
This procedure is continued for one minute at which time the pulse is again checked, as the heart may have stopped beating. If the pulse is still present, EAR is continued at the prescribed rate for further periods of two minutes each, with the pulse being checked for five seconds at the termination of each two minute period, until the casualty recommences breathing.
If at any time during a pulse check it is determined that the pulse is not present, then the rescuer must immediately enter into ECC procedure and perform this in conjunction with EAR procedure. In view of the two discrete procedures involved, it is better for the performance of CPR at this stage to be performed by two rescuers, one performing EAR and the other ECC on the one casualty.
When two rescuers are available, CPR procedure should proceed at the rate of five compressions (ECC) to one inflation (EAR) for an initial period of one minute in the case of an adult, one operator performing ECC in five second cycles at the rate of one compression per second, and the other operator performing EAR timing his/her action to make one inflation of the chest between the fifth compression of one cycle and the first compression of the next.
After the first minute the pulse is checked and if the pulse is returned, ECC is dispensed with and EAR is continued as previously described in two minute periods, with the pulse being further checked after each period. If the pulse is not present, the combined ECC and EAR procedure is continued for two minute periods with the pulse being checked again after each period.
In the case of children, the compression and inflation rate is changed to suit so that 5 compressions are performed at the rate of 100 per minute followed by one inflation.
If only one rescuer is available, then CPR procedure must be altered to accommodate the one person performing both ECC and EAR. In this regard, upon the rescuer determining that the pulse is absent, ECC is performed continuously for 15 chest compressions at a rate of about 80 compressions per minute, whereinafter EAR is performed for two inflations of the lungs over a period of approximately 5 seconds. Thereafter, the cycle of 15 chest compressions and 2 lung inflations is continued at this rate again for an initial period of approximately 1 minute, whereinafter the pulse is checked. If the pulse is still not present, CPR is continued to be performed for periods of two minutes with the pulse being checked at the conclusion of each two minute period for a period of no more than five seconds.
It should be noted that the pulse checking procedure is very important and determines the subsequent procedure to be performed by the rescuer.
As can be appreciated from the above description of CPR procedure, although the procedure is logical, unless it is practised regularly, it is easily forgotten. Indeed, if it is remembered, it can be difficult to perform correctly and accurately, particularly in regard to the timing rates of chest compressions and lung inflation. In practical terms, the need for practising CPR arises only in emergency situations and in the majority of cases a person may never encounter an emergency requiring the performance of CPR technique, or may only encounter the same in an unexpected occasion once or twice in a life time.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an apparatus which can be used by persons untrained in CPR technique or not well practised in the same, to recall and perform prescribed CPR technique, including ECC and EAR in an emergency situation, or in training or other situations requiring its use.
In accordance with one aspect of the present invention, there is provided an apparatus for prompting an operator in the performance of cardio pulmonary resuscitation (CPR) comprising:
input means for sensing an input signal input by the operator, in response to an input prompting signal output by said apparatus;
display means for displaying a plurality of visual prompting signals to said operator;
audible means for outputting an audible prompting signal to said operator; and
control means for controlling the sequencing and operation of said input means, display means and audible means to generate said prompting signals in accordance with a prescribed protocol based on prescribed CPR techniques; wherein:
(i) said input prompting signals are controlled by said control means to prompt the operator to ascertain the presence of a pulse of the casualty, specify the number of rescuers performing the resuscitation, and specify the age status of the casualty;
(ii) said visual prompting signals are controlled by said control means to provide said input prompting signals and also to prompt the operator to perform either or both heart compression and lung inflation on the casualty at a prescribed rate in accordance with said CPR technique; and
(iii) said audible prompting signal is controlled by said control means to supplement said visual prompting signals.
Preferably, said control means sequences and operates said input means, display means and audible means in accordance with said prescribed protocol by:
(i) initially generating said visual prompting signals for a prescribed number and rate of lung inflations in accordance with said CPR technique;
(ii) subsequently generating input prompting signals in the order of firstly prompting the operator to input a said input signal in respect of the result of the pulse check, secondly prompting the operator to input a said input signal in respect of the number of rescuers, and thirdly prompting the operator to input a said input signal in respect of the age status of the casualty;
(iii) next generating said visual prompting signals for heart compression and/or for lung inflation for a first prescribed time period dependent upon said input signals input by the operator in accordance with said CPR technique;
(iv) generating an input prompting signal prompting input of a said input signal for said pulse check after the elapse of said first prescribed time period;
(v) subsequently generating said visual prompting signals for heart compression and/or lung inflation for a second prescribed time period dependent upon said input signal input by the operator for step (iv);
(vi) repeating steps (iii) and (iv) ad infinitum; and wherein said control means only progresses from one step prompting input of a said input signal to the next step upon input of an appropriate said input signal by the operator responsible to the corresponding input prompting signal prompting input of said input signal.
Preferably, said input prompting signals are controlled by said control means to firstly prompt the operator to ascertain whether the casualty is breathing, before prompting for the pulse check result.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood in the light of the following description of several specific embodiments thereof. The description of the first embodiment is made with reference to the accompanying drawings wherein:
FIG. 1 is a perspective of the casing housing the apparatus;
FIG. 2 is a plan view of the key pad and display means layout of the apparatus;
FIGS. 3A-3D form schematic diagram of the hardware circuit of the apparatus; and
FIG. 4 is a functional flow chart depicting the algorithm performed by the software of the apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The first embodiment is directed towards an apparatus for prompting an operator in the performance of CPR which is portable, self contained within a case and internally powered so as to be kept within first aid kits, in vehicles, on industrial sites, in households, near swimming pools and beaches, or any place where an accident may possibly occur which may require the performance of CPR.
As shown at FIG. 1 of the drawings, the casing 11 is constructed in two halves, one forming the base 13 which houses the principal components of the apparatus, and the other forming the lid 15 for closing the outer face 21 of the apparatus.
The base 13 and lid 15 are hingedly interconnected by means of a hinge 17 provided along one edge which incorporates the contact points of a microswitch 19 for switching on power to the apparatus when the lid is open and for switching off power to the apparatus when the lid is closed.
The apparatus essentially comprises input means, display means, audible means and control means, all embodied in electronic circuitry which is housed within the base 13 beneath the outer face 21 of the apparatus.
The input means is associated with a membrane key pad incorporated into the outer face 21 which provides a series of tactile pressure input switches 23 disposed at prescribed locations in the outer face. Accordingly, an input signal is sensed by the input means in response to an operator of the apparatus depressing a switch 23 with finger pressure.
In the present embodiment, seven switches 23 are provided which are arranged into three groups. The first group 23a is disposed on the left hand side of the outer face 21 and provides for the input of an input signal indicating either the presence or absence of a pulse of a casualty on whom CPR is to be performed. The second group 23b provides for the input of an input signal indicating whether there is one or two rescuers. Finally, the third group 23c provides for the input of an input signal indicating the age status of the casualty, i.e. whether it is a baby, child or adult.
The display means is also incorporated into the outer face 21 and comprises a series of light emitting devices in the form of diodes 25 (LEDs) which are arranged into two groups, one group 25a associated and disposed correspondingly adjacent to each respective tactile switch 23 and the other group 25b disposed separately of the tactile switches 23 towards the top of the outer face 21. The first group of LEDs 25a provide an input prompting signal of a visual form to the operator to visually prompt the operator to input an input signal to one of the tactile switches within one of the groups of switches 23. On the other hand, the second group of LEDs 25b provide a visual prompting signal signifying the performance of a heart compression or lung inflation in accordance with the required performance of ECC or EAR, respectively.
The audible means is provided in the form of a pair of piezoelectric buzzers 27, respectively associated with the LEDs 25b. The buzzers 27 output audible prompting signals at two different tones, one high and the other low to respectively supplement the corresponding LEDs 25b. Moreover, one buzzer 27a is dedicated to producing an audible prompting signal at one tone in synchronism with the display means outputting a visual prompting signal from the LED 25b indicating heart compressions, and the other buzzer 27b is dedicated to producing an audible prompting signal in synchronism with the display means outputting a visual prompting signal from the LED 25b indicating lung inflations. In addition to supplementing the operation of the group of LEDs 25b, the buzzers 27 also produce audible prompting signals in the form of input prompting signals to supplement the operation of the LEDs 25a in prompting the operator to input an input signal. In order to distinguish the latter manner of operation of the buzzers from their dedicated operation indicating heart compressions and lung inflations, both buzzers 27 sound in unison when providing an input prompting signal.
In the present embodiment, the buzzers sound providing an input prompting signal only in connection with pulse checks requiring an input signal to be input via the tactile pressure switches 23a.
The control means is housed entirely within the base 13 of the casing and beneath the outer face 21 of the apparatus, and comprises electronic circuitry mounted upon an appropriate circuit board in the conventional way.
In the present embodiment, the control means comprises microprocessor based circuitry which operates in accordance with computer program software stored within an electronic memory provided within the circuitry.
Having particular regard to FIGS. 3A-3D of the drawings, the microprocessor circuitry comprises an 8-bit EPROM micro computer unit U2, a crystal clocking circuit X1, R1, C1 and C2, a reset circuit R2 and C4, an input data bus PA0 to PA6 connected to a serial inport port resistor package SIP1 to SIP8 and the tactile switches 23, and an output data bus PA7 and PB0 to PB7 connected to the LEDs 25a and serial input port resistor package SIP2 to SIP8, and also to the LEDs 25b and piezoelectric buzzers 27 via transistor switches Q1 and Q2. Power is supplied to the circuit by means of a battery BAT and regulator circuit including filtering capacitors C5 and C6 and regulator integrated circuit U6.
As is shown in the drawings, an input data line connected to a tactile switch SW0 to SW6 goes high upon closing the switch 23 and goes low upon opening the switch.
In the case of the LEDs 25a, any of the LEDs LED1 through to LED6 will be illuminated upon the particular output line connected thereto going high. Accordingly, with the output line going low, the LED will be extinguished.
With regard to the heart compression and lung inflation circuits, corresponding heart compression LED LED7 and piezo buzzer HRTBUZ will be respectively activated to produce visual prompting signals simultaneously upon the output line PB7 connected to the base of the transistor Q1 going low. Similarly with respect to the lung inflation circuit, LED8 and piezo electric buzzer LUNGBUZZ will both simultaneously issue a visual prompting signal and audible prompting signal respectively upon the output line PA7 connected to the base of the transistor Q2 going low.
This hardware configuration of the apparatus is operated in accordance with the computer program software stored within the EPROM of the microcomputer unit U2. In the present embodiment the microcomputer unit U2 is in the form of an MC1468705G2 integrated circuit, wherein the size of the EPROM is 2 kilobytes and the computer program software is mask written into the microcomputer in assembly language.
The algorithm of the computer program is represented in flow chart form at FIG. 4 of the accompanying drawings, and as shown includes three principal software routines, the performance of which is determined by the particular input signal which is input to the apparatus by the operator in response to appropriate input prompting signals output by the apparatus.
In this flow chart, the large diamond shaped boxes indicate the output of input prompting signals for decision making purposes, the smaller diamond shaped boxes represent internal decision making performed by the control means, and the rectangular boxes represent internal processing performed initially by the control means and subsequently in response to a previously made decision. The barrel shaped box represents the start program which is performed by the control means after the lid 15 is opened and the switch 19 is closed. As shown at FIG. 3 of the drawings, this program is initiated after the capacitor C4 of the reset circuit charges to a threshold voltage in response to the battery BAT supplying power to the Vcc supply rail, triggering the operation of the microcomputer U2.
As shown in FIG. 4 of the drawings, the first routine is performed immediately after opening the lid and invoking the start program. This routine directs the performance of the five quick breath sequence, whereby the control means selectively outputs appropriate visual and audible prompting signals on the output line PA7 to flash and sound LED8 and LUNGBUZZ were appropriate.
Upon completion of the five breath sequence, the program then proceeds to the first decision making routine which outputs the particular input prompting signal requesting whether a pulse is present on the casualty or not.
After an affirmative input signal is input by the operator, the program proceeds with making an internal decision as to whether the age status of the casualty has been entered, namely whether it is an adult, child or baby. In the case of this status not being previously input, a further input prompting signal is issued requesting an appropriate input signal to be input by the operator regarding this information.
The program then performs an appropriate EAR sequence sub-routine at the appropriate rate for the first time period, dependent upon the age status of the casualty. Accordingly, appropriate output signals are output by the microcomputer U2 along the output line PA7 to operate the lung inflation circuitry.
After completing this sequence, an internal decision is made again to determine whether the previously completed EAR sequence was the first such sequence performed. If so the program returns to the pulse check decision and accordingly issues appropriate input prompting signals to determine further operation. If it was not the first sequence, then the program proceeds with performing the second EAR sequence sub-routine for the second prescribed time period (i.e. two minutes in the case of an adult and scaled down for children and babies).
Upon completing the second EAR sequence sub-routine, the program returns to perform the pulse check decision once more and so on.
It should be noted that the internal decision making sub-routines of the program enables the control means to avoid repeating an earlier program sequence for the input of age status information which was previously entered into the apparatus.
The second and third principal routines involve the performance of CPR technique and are arranged so that the second routine is performed in response to the input means sensing an input signal indicative of there being only one rescuer, and the third routine is performed in response to the input means sensing an input signal indicating that there are two rescuers.
Again, in order to facilitate efficient operation of the apparatus, an internal decision making sub-routine determining whether the number of rescuers has previously been set, is performed prior to the control means providing an external input prompting signal requesting the number of rescuers to be input by the operator into the apparatus. Accordingly, the latter decision making sub-routine can be bypassed when the second or third routines are recycled after performing the pulse check sub-routine at the completion of each cycle.
Upon determining whether there are one or two rescuers available, the program proceeds with the appropriate routine in a similar manner as to the performance of the first routine except that the first and second EAR sequences are replaced by first and second CPR sequences.
It should be noted that at the conclusion of either the first or subsequent second CPR sequences, the program returns to the pulse check sub-routine in each case. This provides for the dual purpose of not only prompting a pulse check, but also facilitates branching out into the EAR sequence alone upon a rescuer sensing the return again of the pulse, whereinafter the ECC aspect of CPR need no longer be performed. Furthermore, the pulse check is maintained to enable the control means to branch out into the full CPR routine, incorporating ECC when a pulse is no longer sensed, thus enabling the EAR sequence alone to be terminated and the full CPR sequence to be invoked.
It should be further noted that in all of these scenarios, the program avoids the performance of redundant sub-routines which would otherwise output input prompting signals for the operator to input information which was already entered during the initial prompting sequence.
Now describing the operation of the apparatus from the view point of an operator, in order to start the apparatus the lid 15 of the casing is opened, whereupon the visual and audible prompting signals are caused to be issued by the control means to flash the LEDs and sound the buzzers, to indicate that the unit is functional. Subsequently, the operator is prompted to perform the five quick breath sequence and then to enter the first input signal, namely whether the pulse of the casualty is absent or present.
If the pulse is present, indicating the need to perform the EAR sequence alone, the control means proceeds directly to request whether the casualty is an adult, baby or child, i.e. the age status. Once the appropriate input signal is input by the operator, the correct resuscitation sequence begins with prompting the required inflation rate for an initial sequence corresponding to approximately one minute duration in the case of an adult, and scaled down with respect to children and babies. After this initial period, the control means then ceases prompting and alerts the rescuer to re-check the pulse by sounding a different intermittent tone and flashing the pulse option LEDs. Should the pulse still be present, then the inflation sequence will continue for two full sequences, (i.e. two minutes in the case of an adult) before again requesting a pulse check. This procedure then repeats continuously.
Should the pulse be no longer present, then the operator will be directed to follow the CPR routine. Moreover, the control means causes the apparatus to proceed with requesting whether one or two rescuers are present. After this information is keyed in, then the apparatus requests whether the patient is an adult, baby or child. Once this is selected then the correct resuscitation sequence begins with prompting the required inflation and heart compression rate for an initial sequence corresponding to approximately one minute duration in the case of an adult.
After this initial period, the control means then ceases prompting and alerts the operator to re-check for a pulse by sounding the different intermittent tone and flashing the pulse option LEDs. Should the pulse still be absent, the sequence will continue now for two full sequences, (i.e. two minutes in the case of an adult) before again requesting a pulse check. If the pulse has returned, then the operator is directly taken to the EAR sequence described above, without the need to re-enter the casualty's status, as this was already entered. Subsequently, the inflation only sequence continues unless the regular pulse check causes the sequence to change again.
The apparatus can be reset to its initial state at any stage by simply closing the lid 15, thereby turning it off. Opening the lid again will commence the start program again. When not in use, the lid is closed, thereby not causing the circuit to consume standby power.
The second embodiment is substantially identical to the preceding embodiment except that the microcomputer unit U2 instead of being an 8-bit EPROM microcomputer unit is a 4-bit EPROM microcomputer unit.
As can be seen in the previous embodiment, the two banks of output data lines PC and PD are not used hence enabling a less expensive 4-bit microcomputer to be utilised. In this embodiment, the chosen microcomputer unit is the uPD7556A integrated circuit.
This microcomputer unit has a smaller onboard EPROM, namely having a capacity of one kilobyte of information, but in the present embodiment this is quite adequate to contain the computer program software.
The apparatus of the present invention has many advantages, including:
1. All prompting for keyboard inputs is annunciated by flashing LEDs alongside the possible choices. Once keyed, the selected choice is signalled by a constantly illuminated LED.
2. The apparatus stops inflation/compression prompting to force the rescuer(s) to check at the correct intervals for the presence or absence of a pulse, and re-enter this information as a safety measure before proceeding.
3. The above pulse checking prompt is initially performed, in the case of an adult, after approximately a one minute duration followed by every two minutes, which is in accordance with correct CPR technique.
4. If after administering CPR, the pulse check determines that the pulse has reappeared, the apparatus directly leads into EAR without further information being required for input.
5. Facility is also provided for changing from an EAR sequence to CPR sequence, and requesting additional information as required regarding the number of rescuers available.
6. The apparatus can be both quickly operated and if required quickly reset by closing its lid.
Importantly, the apparatus requires no more information that is necessary to commence the appropriate resuscitation sequence, including changes in the pulse status which require changes in the CPR sequence to be followed. This simplification of operation saves time and confusion which could otherwise have dire consequences.
It should be appreciated that the scope of the present invention is not limited to the particular embodiments described herein. In particular, minor changes in the computer program software may be envisaged to accommodate for changes in the algorithm. For example, instead of providing separate EAR and CPR sequences, for children and babies, these may be reduced down to a single sequence of operation for both. Furthermore, changes made in the apparatus to accommodate changes made in specifications set down by the Australian Resuscitation Council in the recommended CPR procedure, whereby changes in the algorithm are required, are also envisaged to fall within the scope of the present invention.
It should be appreciated that the scope of the invention is not limited to the scope of the embodiment described herein. | An apparatus for prompting an operator in the performance of cardio pulmonary resuscitation. The apparatus comprises a casing housing, a keypad with input switches, a display with light emitting devices, audible buzzers and a control circuit embodiment in a programmed microprocessor and associated circuitry. Input prompting signals are controlled by the control circuit to prompt the operator to ascertain the presence of a pulse of the casualty, specify the number of rescuers performing the resuscitation, and specifiy the age status of the casualty. The control circuit prompts the operator to perform either or both heart compression and lung inflation on the casualty at a prescribed rate. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to a collapsible avalanche probe for probing for people buried by an avalanche.
BACKGROUND OF THE INVENTION
[0002] Collapsible avalanche probes are known, inter alia, from publication DE 37 29 058 A1. They are employed for probing the relevant terrain after the descent of an avalanche that has buried people. The use of avalanche probes allows the location of an avalanche victim to be pinpointed, particularly in short-range searches. Thus, since the exact position of the buried person has already been determined, an exhausting and time-consuming digging away of snow can be avoided when the avalanche victim is rescued by means of an avalanche shovel.
[0003] Collapsible avalanche probes, which usually consist of a plurality of tubular probe parts that can be assembled when needed, have the advantage that they can be reduced to a very compact pack size when not in use. Since this allows the otherwise bulky avalanche probe to be easily stowed away, this is particularly advantageous for winter sportsmen who carry the avalanche probe solely for the case of an emergency that will hopefully never occur.
[0004] One example of such a collapsible avalanche probe is shown in FIG. 1 . The avalanche probe consists of several tubular probe parts ( 10 , 11 , 12 ) having a connecting cord 2 running therethrough. The connecting cord 2 is usually fastened to the tip 1 of the avalanche probe and can be tensioned by means of a tensioning apparatus 3 at the end of the probe opposite the tip 1 such that the individual probe parts ( 10 , 11 , 12 ) line up against one another. Plug connections 13 between neighboring probe parts ( 10 , 11 , 12 ) guide the probe parts ( 10 , 11 , 12 ) into alignment and provide additional stability. To ensure permanent connection of the probe parts ( 10 , 11 , 12 ), even when probing in snow, is necessary to fix the tensioned connecting cord 2 to prevent the probe parts ( 10 , 11 , 12 ) from pulling apart. A rudimentary scheme for fixing the connecting cord is taught in French publication nos. 2,583,986, where the cord is tied to a cleat mounted to the one of the probe parts. However, it is preferred to fix the connecting cord 2 by use of a clamping apparatus 20 mounted to the last probe part 10 , which is the part most distant from the probe tip 1 .
[0005] One conventional approach to fixing the connecting cord 2 when tensioned is to provide a threaded tension rod on the last probe part 10 . When the avalanche probe is in a folded state, this tension rod is situated within the last probe part 10 , with one end protruding from the last probe part 10 only a little bit. The connecting cord 2 is attached to the other end of the tension rod. By pulling out the tension rod, the connecting cord 2 is tensioned. The tension rod is dimensioned such that a thread on the rod engages a nut provided for this purpose on the last probe part 10 just as the connecting cord 2 is sufficiently tensioned and holds the probe parts ( 10 , 11 , 12 ) together. Via a rotational motion of the tension rod around its own axis, its thread can be screwed into the nut, and the connecting cord 2 can thus be fixed in a tensioned state. This apparatus exhibits several disadvantages. On the one hand, the thread as well as the tension rod protruding from the last probe part are subject to heavy wear. The rod can bend and hamper the assembly and disassembly of the probe. Similarly, the thread of both the nut and the tension rod can be damaged due to corrosion or other mechanical influences. Similarly, the thread frequently fails to function under the extreme conditions of ice and snow. Finally, the screwing in of the tension rod into the nut sphere in severe cold with stiff, glove-protected hands can be difficult.
[0006] To help overcome the difficulty in operating a clamping apparatus such as described above, DE 37 29 058 A1 of the present inventor teaches two structures for fixing the tensioned cord more easily. In a first clamping apparatus, shown in FIG. 2 of the reference, a nut is provided having a non-axial thread such that the nut can be tilted with respect to the last probe part and pulled, then realigned with the last probe part and threadably tightened to fix the connecting cord. The ability to tilt the nut and pull it speeds the fixing procedure, as the nut need not be turned along the full thread range. However, the threads may become disengaged if the nut is inadvertently titled when the probe is in use. In another clamping apparatus, shown in FIG. 3 of the reference, a knot on the connecting cord is pulled into a notch and a cam lever is activated to force the notched part so as to securely tension the connecting cord. While these clamping devices are easier to manipulate than the tension rod discussed above, they still require considerable manipulation to operate.
[0007] Another attempt to simplify fixing the tensioned connecting cord is taught in U.S. Pat. No. 5,966,992. The '992 patent teaches a clamping apparatus where a cable-engaging member is affixed to the connecting cord, and in turn is configured to engage a clamping member. A series of annular grooves on the cable-engaging member can be pulled through the clamping member to tension the connecting cord, but are prevented from moving in the other direction by a spring-loaded pressure member housed in the clamping member. Thus, the connecting cord is fixed automatically as it is pulled to tension it. While the '992 clamping apparatus may provide greater ease in fixing the connecting cord, it appears to do so at the expense of increased wear, as the tensioning force is offset on one side of the cord. The apparatus also may be subject to jamming due to buildup of ice or other foreign matter in the clamping mechanism; the '992 patent suggests that the annular grooves are prone to ice build-up, as it teaches that ice in the annular grooves is crushed by the spring-loaded pressure member; however, there is no discussion of other possible causes of jamming. Furthermore, the release lever moves normal to the probe axis and is exposed to possible inadvertent release.
SUMMARY OF THE INVENTION
[0008] The present invention provides an avalanche probe that can be assembled, used and disassembled in a simple, safe and wear-free manner.
[0009] This avalanche probe comprises at least a first and a second tubular probe part that can be brought into plug connection, a connecting cord situated inside the probe parts, one end of which is in connection with the first probe part, and the other end of which is in connection with a tensioning apparatus, wherein the connecting cord is tensionable by means of the tensioning apparatus and is fixable in a clamping apparatus situated on the second probe part in such a manner that, in a tensioned state, all probe parts are held against one another in plug connection and, in an untensioned state, the probe parts are movable relative to one another. In the present invention, the clamping apparatus comprises an inner sleeve, having a first channel through which the connecting cord passes, and an outer sleeve, having a second channel in which the inner sleeve is slidably situated in such a manner along a longitudinal axis of the outer sleeve that the inner sleeve can be brought from a release position to a clamping position in which at least one clamping element engages the first channel in such a manner that the connecting cord running through the first channel is fixedly held in the clamping apparatus.
[0010] Accordingly, the advantage of the apparatus can be particularly seen in that the clamping apparatus for fixing the connecting cord consists, in essence, of three parts, namely the inner sleeve, the clamping element and the outer sleeve. The connecting cord running through the inside of the probe is fed through the inner sleeve. The inner sleeve can be slid back and forth along the longitudinal axis of the outer sleeve. If the inner sleeve is located in the clamping position, then a clamping element engages the second channel via the wall of the inner sleeve and thus fixes the connecting cord.
[0011] Particularly advantageous in this case is that a simple sliding motion from the release position into the clamping position suffices to fix the connecting cord. If the tensioning force of the connecting cord acts so as to automatically bring the inner sleeve into the clamping position via appropriate friction, the clamping apparatus can fix the tensioned connecting cord without further manipulation.
[0012] Preferably, the inner sleeve comprises at least one recess that connects the first and second channels and respectively receives a clamping element. This recess can be, for example, a bore that has been formed through the wall of the inner sleeve at a right angle to the longitudinal axis of the second channel. In this manner, the relative motion between the inner sleeve and the outer sleeve that occurs during a sliding from the release position to the clamping position can be used to redirect the clamping element via the recess in the direction of the connecting cord and to exert the fixing force on the connecting cord.
[0013] Preferably, the inner sleeve comprises exactly three mutually opposite-lying clamping elements. The three clamping elements are situated in a plane orthogonal to the longitudinal axis of the second channel and preferably form, in respective pairs with the midpoint of the second channel, essentially identically large angles. A cord tensioned in this manner is securely held, yet can be easily released from the tensioned position since each of the three clamping elements exerts an equal force.
[0014] In the manufacturing of avalanche probe, it is beneficial and advantageous to manufacture the individual elements from materials that do not rust. The clamping elements are preferably manufactured from plastic.
[0015] Preferably, the clamping element comprises a sphere. This sphere that is situated in the aforementioned recess glides along the inner wall of the outer sleeve without substantial friction during a sliding of the inner sleeve from the clamping position into the release position and back again. Thus, due to the marginal friction, this motion requires only minor effort.
[0016] Preferably, the diameter of the sphere is larger than the thickness of the wall of the inner sleeve in the direct vicinity of the respective recess so that the sphere is clampable between the outer sleeve and the connecting cord. This means that the sphere is dimensioned to be so large that it protrudes either into the first channel or into the second channel, or partially into both channels. In this manner, force can be exerted via the sphere onto the connecting cord running through the first channel. This force serves to fix the connecting cord when tensioned.
[0017] Preferably, the diameter of the sphere is larger than or equal to that of the connecting cord. Preferred dimensions of the connecting cord are, in the case of a metal cable, roughly 1.6 mm and, in the case of a Kevlar cable, roughly 2 mm. Accordingly, the spheres exhibit a diameter of roughly 2.5 mm to 3.0 mm. Through the use of advantages ratios between the cord and sphere diameter, a secure clamping can be ensured, particularly when three spheres are used that are mutually oppositely situated in a plane.
[0018] Preferably, the second channel of the outer sleeve comprises a section that conically tapers in the direction of the first probe part and that forms a ramp in the radially inward (axial) direction of the second channel, which ramp tensions at least one clamping element in the direction of the connecting cord during motion of the inner sleeve from the release position into the clamping position. Thus, at least one clamping element, e.g. the sphere held in the recess, glides up the ramp during this motion of the inner sleeve and is thus increasingly pressed in the axial direction of the second channel. The fixing operation carried out in this manner can be reversed via a motion of the inner sleeve from the clamping position into the release position. The sphere/clamping element glides down the ramp, away from the longitudinal axis, and increasingly gains play and no longer fixes the cord.
[0019] Advantageously, an outer wall of the inner sleeve comprises at least one conical section in which at least one clamping element is situated and that is formed essentially parallel to the conical section of the outer sleeve. Thus, in the clamping position, a conical section of the outer sleeve lies respectively opposite a conical section of the inner sleeve.
[0020] To avoid losing functionality of the clamping apparatus due to dirt or icing, it has at least one seal that seals the first and second channels from the ambient environment. Preferably, several seals are configured such that a transporting of dirt or moisture into the interior of the clamping apparatus is not possible via either the relative motion of the connecting cord or the motion of the inner sleeve relative to the outer sleeve from the clamping position to the release position and back.
[0021] If a spring element of the clamping apparatus biases the inner sleeve into the clamping position, then an automatic fixing of the connecting cord is effected. If the connecting cord is further tensioned, then the tensioning motion preferably acts counter to the spring force and brings the inner sleeve from the clamping position into the release position. After the tensioning of the connecting cord, the inner sleeve, driven by the spring element, returns to the clamping position. Preferably, the spring element is a helical spring or a conical helical spring.
[0022] To easily undo the fixing of the connecting cord, an actuating handle can be provided on the outer end of the inner sleeve facing away from the second probe part, by means of which the inner sleeve can be brought from the clamping position into the release position.
[0023] To simplify operation of the actuating handle, a grip can be provided on the second probe part to assist in tensioning the cord and in pulling the inner sleeve to the release position. This is particularly advantageous when one considers that the probes are used in snow and ice and that, accordingly, the users usually wear gloves.
[0024] Preferably, the outer sleeve comprises a stopping apparatus that limits a motion of the inner sleeve, at least in a tensioned state, opposite the tensioning action of the connecting cord. Such a stopping apparatus is configured and adapted such that a seizing or wedging of the inner sleeve in the first channel particularly due to the conical tapering of the outer sleeve is precluded. As a result, the motion of the inner sleeve is as smooth-running as possible.
[0025] The inner sleeve can include at least one notch opposed to each of the clamping elements for fixing reception of the connecting cord in the clamping position.
[0026] To ensure simple maintenance of the clamping apparatus, an adapter into which the clamping apparatus can be detachably screwed can be provided on the second probe part. For example, this adapter can be glued to the second probe part. Instead of a screwing of the clamping apparatus into the adapter or even directly into the probe part, a snapping mechanism for securing the clamping apparatus in the adaptor is also conceivable.
[0027] Further details, advantages and embodiments of the invention can be taken from the following description of two preferred embodiments with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a partially exploded isometric view of a prior art avalanche probe with a clamping apparatus.
[0029] FIG. 2 a is an exploded isometric view of a portion of the avalanche probe of FIG. 1 which has a clamping apparatus of one embodiment of the present invention.
[0030] FIG. 2 b is an exploded isometric view of a portion of the avalanche probe of FIG. 1 which has a clamping apparatus of another embodiment of the present invention.
[0031] FIG. 3 a is a cross-section view of the clamping apparatus shown in FIG. 2 a.
[0032] FIG. 3 b is a cross-section view of the clamping apparatus shown in FIG. 2 b.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] In following discussion of the figures illustrating the avalanche probe, the same reference numbers are used for identical and functionally identical parts.
[0034] As noted in the background section of the application, FIG. 1 is a representation of a prior art collapsible avalanche probe. The avalanche probe has several tubular probe parts 10 , 11 , 11 ′ and 12 that can be plug-connected to one another. A first probe part 12 and a second probe part 10 (not shown in its plug-connected position) respectively form the beginning and the end of the probe, and can be stuck together with the intermediate probe sections ( 11 , 11 ′) attached therebetween. While only two intermediate probe sections ( 11 , 11 ′) are shown in FIG. 1 , it is typically preferred to employ more to reduce the length of the probe parts; however, a two-part probe could be employed using only the first probe part 12 and the second probe part 10 . To allow easier insertion of the probe into the snow, a tip 1 is attached at an extreme end of the first probe part 12 . A clamping apparatus 20 is located on the second probe part 10 that forms the other end of the avalanche probe. A connecting cord 2 runs in the interior of the probe parts ( 10 , 11 , 11 ′, 12 ). The connecting cord 2 is fixedly connected, via the one end, to the first probe part 10 and can be tensioned via a tensioning apparatus 3 mounted on the other end which can be grasped by the user and pulled to apply tension to the connecting cord 2 . The tensioned connecting cord 2 runs through the interior of the clamping apparatus 20 and is fixed in its tensioned state by means of the clamping apparatus 20 .
[0035] FIG. 2 a illustrates an exploded view of a first embodiment of an improved clamping apparatus 20 ′. This figure shows the end section of the second probe part 10 from which the connecting cord 2 extends. The connecting cord 2 runs through an inner sleeve 21 of the clamping apparatus 20 ′. Further constructional elements of the clamping apparatus 20 ′ shown here are an outer sleeve 22 , three spheres ( 30 , 31 , 32 ) that form the clamping elements of this embodiment, a conical helical spring 25 , an annular cap 29 for closing off the outer sleeve 22 , as well as an actuating handle 26 .
[0036] The function and position of the individual constructional elements of the clamping apparatus 20 ′ shown in FIG. 2 a can be better understood by viewing FIG. 3 a , which illustrates the assembled clamping apparatus 20 ′ in cross-section along a longitudinal axis 19 of the second probe part 12 . The clamping apparatus 20 ′ is situated, in this case, largely inside the second probe part 10 . The outer sleeve 22 is situated inside, parallel to the longitudinal axis 19 of the second probe part 10 , and is fixedly glued to same, pressed into it, or otherwise affixed therein. In turn, the inner sleeve 21 is situated in the inside of the outer sleeve 22 , residing in a second channel ( 22 a ) of the outer sleeve 22 . The inner sleeve 21 is also parallel to the longitudinal axis 19 of the second probe part 10 . When the inner sleeve 21 is moved along this longitudinal axis 19 , it can be brought from a clamping position, in which the inner sleeve 21 projects further into the interior of the second probe part 10 , into a release position, where the projection of the inner sleeve 21 into the interior of the second probe part 10 is reduced. The annular cap 29 is screwed into a thread of the outer sleeve 22 and clasps around the inner sleeve 21 in such a manner that the outer end of the outer sleeve 22 is closed off. The conical helical spring 25 engages the inner sleeve 21 and the annular cap 29 of the outer sleeve 22 in such a manner that the spring force holds the inner sleeve 21 in the clamping position. In order to counteract this spring force to bring the inner sleeve 21 from the clamping position into the release position, an actuating handle 26 which can be readily grasped and pulled by the user is provided at the outermost end of the inner sleeve 21 . For simple maintenance of the clamping apparatus 20 , the cap 29 can be threadably removed.
[0037] An inner (first) channel ( 21 a ) runs along the longitudinal axis 19 in the interior of the inner sleeve 21 as well as through the actuating handle 26 . The connecting cord 2 passes through the inner channel ( 21 a ), as shown in FIG. 2 a . The sphere 30 is situated in a recess 23 that traverses a section of the inner sleeve 21 . This sphere 30 is dimensioned such that it projects above the recess 23 . The outer sleeve 22 is formed with a conical ramp extending in the direction of the longitudinal axis 19 of the second probe part 10 ; thus, the second channel ( 22 a ) of the outer sleeve 22 tapers in such a manner that, when the inner sleeve 21 is in the clamping position, the sphere 30 projects into the first channel ( 21 a ) of the inner sleeve 21 and thus fixes the connecting cord 2 which passes therethrough (cf. FIG. 2 a ). In the release position, the sphere 30 has more play between the inner sleeve 21 and the outer sleeve 22 , and thus the sphere 30 is not pressed into the first channel ( 21 a ) of the inner sleeve 21 when the inner sleeve 21 is in the release position. Preferably, the inner sleeve 21 is formed with a conically tapered portion that parallels the conical ramp of the outer sleeve 22 . In order to avoid jamming of the inner sleeve 21 against the conically tapered outer sleeve 22 , a stopping apparatus 28 is provided at the inner end of the outer sleeve 22 . When the connecting cord 20 has a somewhat deformable cross section, a notch 24 can be provided in the inner sleeve 21 positioned opposite the recess 23 to more securely fix the cord in the clamping position. However, such a notch 24 may make release of the connecting cord 2 more difficult.
[0038] Although only one sphere 30 is depicted in the cross-section view of FIG. 3 a , three spheres ( 30 , 31 , 32 ) with corresponding recesses 23 are provided, as can be discerned from FIG. 2 a . Due to the tapering of the second channel ( 22 a ) of the outer sleeve 22 , each of the three spheres ( 30 , 31 , 32 ) is pressed first channel ( 21 a ) of the inner sleeve 21 when the inner sleeve 21 is in the clamping position. Thus, in the clamping position, the connecting cord 2 (shown in FIG. 2 a ) is jammed between the three spheres ( 30 , 31 , 32 ).
[0039] FIGS. 2 b and 3 b show a second embodiment of the improved clamping apparatus 20 ′ for use in the collapsible avalanche probe shown in FIG. 1 . Analogous to FIGS. 2 a and 3 a , FIG. 2 b shows an exploded isometric view, and FIG. 3 b shows a cross-section of the assembled clamping apparatus 20 ′. These Figures show a connecting cord 2 , an actuating handle 26 , a conical helical spring 25 , an inner sleeve 21 , three spheres ( 30 , 31 , 32 ) that serve as clamping elements, an annular cap 29 and an outer sleeve 22 . Additionally, the second embodiment of the clamping apparatus 20 ′ has an adapter 4 that is fixed into the end of the second probe part 10 . The adapter 4 serves as a coupling piece between the second probe part 10 and the clamping apparatus 20 ′. The clamping apparatus 20 ′ is removably screwed into the adapter 4 .
[0040] The second embodiment of the clamping apparatus 20 ′ furthermore comprises a first seal 40 , a second seal 41 , and a third seal 42 . These seals ( 40 , 41 , 42 ) serve to prevent the ingress of snow and other contaminants into the clamping apparatus 20 ′. As can be seen from FIG. 3 b , the first seal 40 is situated at the outer end of the inner sleeve 21 , facing away from the second probe part 10 , and is formed in such a manner that it clasps around the connecting cord 2 (cf. FIG. 2 b ). The second seal 41 is situated at the inner end of the outer sleeve 22 and also clasps around the connecting cord 2 . The third seal 42 is situated at the outer end of the outer sleeve 22 and clasps around the inner sleeve 21 . Since the inner sleeve 21 projects from the outer sleeve 22 in order to receive the actuating handle 26 over the outer sleeve 22 at the end thereof that faces away from the probe part 10 , the third seal 42 is necessary to close off a gap between the inner sleeve 21 and the outer sleeve 22 .
[0041] As regards the second embodiment of the clamping apparatus 20 ′, it should also be noted that the actuating handle 26 of this embodiment has an umbrella-shaped form and a grip 27 is provided on the outer wall of the outer sleeve 22 for improving the operability of the actuating handle 26 by allowing the user to more readily grasp the outer sleeve 22 when pulling the actuating handle 26 to move the inner sleeve to the release position.
[0042] While the novel features of the present invention have been described in terms of particular embodiments and preferred applications, it should be appreciated by one skilled in the art that substitution of materials and modification of details obviously can be made without departing from the spirit of the invention. | An avalanche probe for locating and rescuing people buried by an avalanche is collapsible, having several probe segments which allow the probe to be folded to a compact unit that can be quickly and easily assembled for use. A connecting cord passes through the probe segments and fastens to a probe tip. Applying tension to the cord draws the segments into alignment. A clamping mechanism maintains the tension on the cord in such a manner that the probe segments are fixedly and securely held against one another. The clamping mechanism provides two interpenetrating elements, an outer element and an inner element having a passage therethrough. At least one clamping element passes into the central passage and is forcibly engaged with the cord as the interpenetration of the elements increases. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to trip lever assemblies. It is especially well suited to provide toilet trip lever assemblies that control flush valves that are located at or near the bottom of toilet tanks.
[0004] A variety of toilet trip lever assemblies are well known. These assemblies are typically mounted on a side wall of a toilet tank with a handle positioned outside the tank and linked to a stem. The stem is rotatably mounted through the tank wall. A trip arm (which typically extends along the tank wall from the stem) is connected to the stem inside the toilet tank.
[0005] One end of the trip arm is connected to a chain, which in turn is linked to the usual toilet tank outlet valve. When a user rotates the handle, the trip arm is caused to pivot, thereby moving up its outer end, which in turn yanks the chain up, and thus the tank outlet valve.
[0006] Depending upon space limitations in the tank, and the exterior configuration of the tank desired, it is sometimes desirable that rotation of the handle produce a pivoting of the trip arm in a plane which is perpendicular (not parallel) to the wall through which the lever is mounted. There have been some assemblies which have achieved this result.
[0007] For example, U.S. Pat. No. 1,555,620 provided a toilet trip lever in which both the outer handle and the inner lever arm pivoted perpendicular to the tank wall. Unfortunately, this required the handle to jut out a significant distance from the tank wall, and provided poor leverage characteristics.
[0008] U.S. Pat. No. 3,419,912 disclosed an improved perpendicular type toilet trip lever (where the outer handle rotated in a conventional manner). A very short arm pivoted with the stem that passed through the wall. That arm in turn pushed up a perpendicular lever arm that was supported on a bracket. Because of the construction of the mechanism, a relatively large angle of rotation of the handle was required to activate the valve. Furthermore, the device was relatively costly to manufacture and assemble.
[0009] U.S. Pat. No. 4,575,881 provided another perpendicular type toilet trip lever. However, the parts of that assembly were somewhat difficult to adjust to account for certain variations in the toilet wall thickness. Also, certain of the plastic parts could break if not carefully handled.
[0010] Therefore, a need still exists for an improved “perpendicular” type toilet trip lever assembly.
SUMMARY OF THE INVENTION
[0011] In one aspect the present invention provides a trip lever assembly mountable through a hole of a tank wall. There is a rotatable stem extendable through the hole, a handle mountable to an outer end of the stem, and an arm mountable to an inner end of the stem so as to rotate with the stem, the arm then being extendable along the wall.
[0012] There is also a support mountable inside the tank, and a lever mountable for pivoting on the support, with the lever then extending from a position adjacent the wall towards a position farther away from the wall. When the trip lever assembly is mounted through said tank wall hole, rotation of the handle can cause the arm to drive an end of the lever which is adjacent the wall down, and an opposite end of the lever up.
[0013] In preferred forms there is a chain linked to the opposite end of the lever and a flush valve link to the chain. Also, the stem can be surrounded by a bushing, and the bushing can cooperate with the handle to limit rotational movement of the handle. The bushing can be outwardly threaded, and a nut can be provided with internal threads to thread onto the bushing threads.
[0014] There can also be an escutcheon positionable adjacent the handle outside the tank wall, the escutcheon having a locating member for locating the escutcheon in the hole of the tank wall. The bushing can include ribs or ridges sized and dimensioned to deform as they are inserted into the escutcheon to provide a tight fit.
[0015] In especially preferred forms a contact surface of each of the arm and lever (which contact each other) are a rolled surface, the support is an L-bracket with a mounting hole for mounting the L-bracket over the hole in the wall, the mounting hole includes a rolled tab, and the support has another hole into which the arm projects.
[0016] In another aspect the invention provides a combined toilet tank and trip lever assembly. There is a tank having a bottom wall and surrounding side walls. There is a hole through a side wall. There is also a flush valve mounted in a lower portion of the tank.
[0017] A rotatable stem extends through the hole in the tank side wall, a handle is mounted to an outer end of the stem, and an arm is mounted to an inner end of the stem so as to rotate with the stem, the arm then extending essentially parallel to the side wall through which the stem extends.
[0018] There is also a support mounted inside the tank. A lever is mounted for pivoting on the support, with the lever then extending essentially perpendicular to the side wall through which the stem extends between a position adjacent that wall towards a position farther away from that wall. Rotation of the handle causes the arm to drive a part of the lever down, and an opposite part of the lever up.
[0019] The location of the pivot point along the support is such that a relatively small angle of rotation of the stem causes the lever to lift the chain sufficiently to flush the toilet. Rotation of the stem beyond the desired point is limited by interaction of the handle and bushing, thereby preventing the arm from “clinking” or “tapping” on the bottom side of the tank lid.
[0020] The advantage of the present invention therefore include, without limitation, providing a perpendicular type toilet trip lever which is easy to produce, easy to assemble, inexpensive, and reliable. Relatively small movement of the handle creates the necessary movement of the chain. Still other advantages of the present invention will be apparent from the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a view, partially in vertical cross section, of a toilet tank employing a trip lever assembly of the present invention, with the lever assembly mounted on a side wall;
[0022] [0022]FIG. 2 is an exploded view of the trip lever assembly, with a fragmented portion of the tank wall also shown;
[0023] [0023]FIG. 3 is a sectional view taken along line 3 - 3 of FIG. 4;
[0024] [0024]FIG. 4 is a view taken along line 4 - 4 of FIG. 6;
[0025] [0025]FIG. 5 is a view taken along line 5 - 5 of FIG. 6; FIG. 5A is a further enlarged view taken of the detail portion 5 A- 5 A of FIG. 5;
[0026] [0026]FIG. 6 is a perspective view of the trip lever assembly of the present invention, mounted on a toilet tank wall, and in a position where the flush valve of the tank would be seated in a closed position;
[0027] [0027]FIG. 7 is a view similar to FIG. 6, but with the valve in a position where the flush valve would be above its seated position so as to be open; and
[0028] [0028]FIG. 8 is a view similar to FIG. 3, but with the handle in the FIG. 7 position in dotted lines.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] [0029]FIG. 1 shows a toilet trip lever assembly 10 of the present invention mounted on a side wall 11 of a conventional toilet tank 12 . An outlet pipe 13 leads to the usual toilet bowl (not shown), and is sealed by an outlet flush valve 14 . It should be appreciated that the specifics of the flush valve mechanism are not critical, and that a wide variety of other such mechanisms which are activated by an upward yank can be used with the present invention.
[0030] The usual inlet pipe 15 is connected to a conventional inlet valve 16 , which is controlled by a float 17 in a conventional manner. A chain 18 or other linkage connects the trip assembly 10 of the present invention to the outlet flush valve 14 , to control lifting of the outlet valve 14 off of its seat when the trip assembly 10 is operated. Lifting the valve 14 off of its seat on the outlet pipe 13 causes the toilet to flush, as is well known.
[0031] Referring now to FIG. 2, an exploded view of the toilet trip lever assembly 10 of the present invention is shown. An actuating assembly has a handle 20 , a bushing 24 , and a rotatable trip pin 32 . The pin 32 is coupled to a stem 42 of the handle 20 with a threaded fastener 34 . The handle 20 is provided on the outside of the tank wall 11 , with a decorative escutcheon 22 , while the bushing 24 and trip pin 32 extend through an aperture 25 of the toilet tank wall 11 .
[0032] An arm assembly has an L-bracket 26 and lever arm 28 , which pivots about a pin 80 . The L-bracket is located inside the toilet tank against the wall 11 . The actuating assembly and arm assembly are clamped to the tank wall with a nut 30 threading onto threads 52 of the bushing 24 .
[0033] The handle 20 is preferably substantially rectangular, with a planar front wall 35 and side walls 37 . First and second vertical cross bars 36 and 38 extend from the top and bottom side walls 37 to a stem 42 positioned at a substantially central location between the top and bottom wall. The stem 42 extends from the front wall 35 of the handle 20 in a direction substantially perpendicular to the front wall 35 . A horizontal cross bar 40 extends from a side wall 37 to the stem 42 . The horizontal cross bar 40 acts as a rotational stop for the handle 20 as described more fully below.
[0034] The distal end of the stem 42 includes a threaded receptacle 46 and a generally rectangular locator element 44 sized and dimensioned to mate with the rotatable trip pin 32 . The bushing 24 is received in the handle 20 . The outwardly facing end of the bushing 24 comprises a planar circular element 47 that includes a generally circular ridge 48 extending outward in a direction substantially perpendicular to the planar element 47 .
[0035] An opening 50 defined in the circular ridge 48 provides first and second stop elements 49 and 51 . The stop elements 49 and 51 work with the horizontal cross bar 40 in the handle 20 to limit rotation of the handle 20 . The back side of the bushing 24 comprises a threaded sleeve 52 , a square mounting section 54 and associated “crush ribs” or ridges 56 . The square mounting section 54 is sized and dimensioned to slide into an aperture in the escutcheon 22 . As the square mounting 54 is slid into position, the associated ridges 56 are deformed or crushed to provide a tight fit between the bushing 24 and the escutcheon 22 , thereby locking the bushing in a substantially stationary position as shown in FIG. 5A. The escutcheon 22 includes a generally rectangular aperture 58 sized and dimensioned to receive the mounting section 54 of the bushing 24 .
[0036] Referring now to FIG. 5, the bushing 24 is inserted into the aperture 58 from the front of the escutcheon 22 until the mounting section 54 and associated ridges 56 extend through and are deformed are crushed against the aperture 58 defined in the escutcheon 22 to provide a tight fit, as shown in FIG. 5A. First and second semicircular locating ridges 60 and 62 extend in a generally perpendicular position from the escutcheon 22 and provide a means for locating the escutcheon 22 within the aperture 25 of the tank wall 11 .
[0037] Referring now to FIG. 7, the L-bracket 26 comprises first and second perpendicular walls 64 and 66 . When assembled the first wall 64 is positioned against the internal tank wall 11 , in a plane substantially parallel to the tank wall 11 . The wall 64 includes an aperture which is positioned around the aperture 25 in the tank wall 11 and which receives the threaded shaft 52 of the bushing 24 .
[0038] As seen in FIG. 2, the side walls of the aperture 68 each include a rolled tab 74 and 76 which is a piece of the L-bracket 26 which is rolled substantially 90° backwards and is sized and dimensioned to provide a locating element for attaching the L-bracket 26 to the aperture 25 in the toilet wall 11 . The aperture 68 further includes vertically-directed tabs 70 and 72 which are used to locate the bushing 24 in the aperture 68 and to limit motion of the bushing 24 vertically.
[0039] The second wall 66 extends further into the tank in a direction substantially perpendicular to the tank wall 11 . The arm 28 is coupled to the outer side of the wall 66 on the side furthest from the first wall 64 the L-bracket 26 . The arm 28 is coupled to the wall 66 through a glide bearing 82 and a pivot pin 80 . The pivot pin 80 can comprise a threaded fastener or other devices known to those of skill in the art, but preferably comprises a rivet which is inexpensive and easy to manufacture.
[0040] At a first distal end of the arm 28 , an aperture 84 is defined for receiving the usual chain 18 or another linkage for operating the outlet flush valve 14 . At the opposing distal end of the arm 28 is a lever section 86 which is activated by the trip pin 32 to activate the arm 28 .
[0041] The location of the pivot point defined by the pin 80 is provided in the L-bracket 26 at a location selected to provide a relatively large movement of the aperture 84 for a minimal rotation of the lever section 86 . Furthermore, the lever section 86 is vertically offset from the axis 81 (FIG. 7) at a location vertically below the pivot pin 80 , thereby also aiding in providing a flush with a small axis of rotation of the handle. The top of the lever section 86 is rolled, providing a surface of contact between the lever section 86 and the rotation trip pin 32 . The lever section 86 is accessible to the trip pin 32 through an aperture 78 in the wall 66 of the L-bracket 26 .
[0042] The rotatable trip pin 32 mounts on the square mounting post 44 of the stem 42 of the handle 20 . The rotatable trip pin 32 further comprises a lever section 90 which, as described with reference to the lever section 86 above, comprises a rolled surface. The trip pin 32 is aligned along an axis 83 (FIG. 7) substantially parallel to the tank wall 11 .
[0043] Assembly of the device can be achieved quickly, and without requiring special tools. The bushing 24 includes crush ribs or ridges 56 which deform as they are slid into the escutcheon 22 to provide a tight fit. The escutcheon 22 further includes locating ridges 60 and 62 which are sized and dimensioned to quickly align the escutcheon with the aperture 25 in the tank wall 11 . Similarly, the rolled tabs 74 and 76 in the aperture 78 of the L-bracket 26 provides for simplified alignment of the L-bracket 26 in the aperture 25 of the tank wall 11 . Other features which simplify manufacturing include the alignment tabs 70 and 72 in the aperture 78 of the L-bracket 26 , which align the bushing 24 in the aperture 25 , and the mounting element at the distal end of the stem 42 which mates to the aperture in the trip pin 32 .
[0044] Furthermore, although these elements simplify alignment of the constituent parts in the trip lever assembly 10 , each of these elements includes sufficient “play” to allow for alignment despite variations in the vitreous china used to make the tank. Additionally, the arm 28 preferably comprises a malleable metal material which can be bent as necessary to account for such variations in the tank.
[0045] To assemble the trip lever assembly 10 , the escutcheon 22 is aligned with the aperture 25 in the tank wall 11 . The actuating assembly comprising the handle 20 , bushing 24 , and trip lever 32 is then slid through the escutcheon 22 and the aperture 25 in the tank wall 11 , such that the threaded sleeve 52 of the bushing 24 extends through the aperture 25 . The aperture 78 of the L-bracket 26 is aligned over the sleeve 52 and around the aperture 25 from the inside of the tank wall 11 , such that the arm 28 extends in a direction substantially perpendicular to the tank wall 11 . When the L-bracket 26 and escutcheon 22 are in place, a threaded nut 30 is coupled over the sleeve 52 , locking the bushing 24 , L-bracket 26 , and escutcheon 22 in place on the tank wall 11 .
[0046] As assembled, the handle 20 aligned such that the horizontal cross bar 40 is positioned in the aperture 50 between the stop surfaces 49 and 51 . In operation the handle 20 is turned in a clockwise direction by a user to trigger the lift arm 28 from the “closed” position of FIG. 6 to the “open” position of FIG. 7, thereby selectively flushing the toilet.
[0047] As the handle 20 is turned, the horizontal cross bar 40 inside of the handle 20 is rotated about the stem 42 . Rotation of the handle 20 is limited by the stop elements 49 and 51 of the bushing 24 , which is held stationary by the nut 30 , which locks the bushing in place. The stop elements 49 and 51 prevent the horizontal cross bar 40 from rotating beyond a defined angle of rotation, and therefore further prevent unwanted interaction or “clinking” between the metal arm 28 and the top of the toilet tank.
[0048] As the handle 20 is turned, the stem 42 is rotated, thereby causing the trip pin 32 to rotate toward the lever section 86 of the arm 28 . As the trip pin 32 is rotated, the rolled portion of the trip pin 32 contacts the rolled portion of the lever section 86 causing the arm 28 to pivot about the pin 80 as shown in FIG. 7. Rotation about the pin 80 causes the lever section 86 to rotate downward toward the bottom of the tank and the opposing end of the arm 28 , including the aperture 84 , to rotate upward toward the top of the tank.
[0049] As the aperture 84 moves up, the outlet valve 14 coupled to the valve is lifted, as shown in FIG. 1, causing the water to flush through the pipe 13 . The slide bearing 82 limits both noise and friction between the pin 80 and arm 28 as the arm rotates. The rolled surfaces of the trip pin 32 and lever section 86 produce relatively little noise on contact, and further provide a longer-wearing contact surface. Therefore, the design of the present invention provides a relatively quiet but durable construction.
[0050] Furthermore, the relative positioning of the pivot point about the pin 80 in the arm 28 assures that a relatively small angle of rotation of the handle will provide a sufficient rise of the aperture 84 to activate the valve 14 , and to provide a flush of the toilet. As the operator rotates the handle 20 in a clockwise direction, an angle of rotation in a range of about twenty-eight to thirty degrees effects a flush. Preferably, the angle of rotation is twenty-nine degrees plus or minus half of a degree.
[0051] As will be apparent to those of ordinary skill in the art, a preferred embodiment of the invention has been described above. Modifications and variations to the preferred embodiment may be made within the spirit and scope of the invention. For example, variations in the angle of rotation of the handle and the lift of the arm can be effected by modifying the pivot point of the arm 28 , the length of the arm 28 , and the position of the stop elements 49 and 51 in the bushing 24 . Furthermore, although a rectangular handle has been described, handles in a variety of shapes can be employed. Therefore, the invention is not to be limited to the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced.
Industrial Applicability
[0052] The present invention provides a toilet trip lever assembly. | A toilet trip lever assembly provides a lever arm that extends in the tank perpendicular to the tank wall. As an outer handle is rotated, it drives a stem, which in turn drives an arm inside the tank that extends parallel to the tank wall, which pushes down an end of a lever. A support holds the lever such that downward movement of that end of the lever drives the opposite end of the lever up. The opposite end of the lever is connected to a linkage to a flush valve. | 4 |
RELATED APPLICATIONS
[0001] This application is related to U.S. patent application Ser. No. 10/884,643, filed Jul. 2, 2004 and entitled “Stripe Removal System”, U.S. patent application Ser. No. 11/340,738 filed Jan. 5, 2006 and entitled “Transportable Holding Tank for Stripe Removal Systems” U.S. patent application Ser. No. 11/340,104 filed Jan. 26, 2006 and entitled “Mobile Mark Removal System” U.S. patent application entitled “Combined Grinder and Waterblaster for Stripe Removal System” filed Mar. 3, 2006 U.S. Express Mail number EV531127416US, the contents of which are incorporated herein in F their entirety.
FIELD OF THE INVENTION
[0002] This invention relates to the field of high pressure water cleaning devices for highways, runways, parking decks, factory floors and other marked surfaces.
PRIOR ART BACKGROUND
[0003] The use of paint stripes on road surfaces is the accepted method to indicate vehicle lanes, crossing lanes, parking areas and numerous other indicators. Various pavement marking techniques are well known in the art, including the use of traffic paint, thermoplastics, epoxy paints and preformed tapes. Most pavement marking systems are intended to be as durable and permanent as possible, and resistant to weathering and wear from traffic. Common road surfaces are asphalt and concrete. The removal of such striping is typically required when the road is to be resurfaced or if the indication is to be changed.
[0004] When polymers such as paint or plastic are used for roadway marking, the surface of the pavement is penetrated from ⅛-⅜inch, so that mere surface removal of the marking material is not sufficient to remove the marking. Therefore, current pavement marking removal machines often employ various forms of cutting devices to remove the marking material, as well as a portion of the underlying layer of pavement material in order to effectively remove painted lines.
[0005] Commonly known methods for removal of such markings typically include the use of abrasive grinding wheels, material removing cutters, or blasting of abrasive particles against the material to be removed. However, the use of these devices often results in undesirable grooves in the pavement surface.
[0006] For example, one type of cutting machine is disclosed in U.S. Pat. No. 5,236,278, known as a “Road Pro” and is manufactured by Dickson Industries, Inc. This type of machine employs parallel passive shafts that extend between circular rotating end plates. Hardened steel star wheels are carried on the parallel passive shafts, and these star wheels strike and abrade the pavement surface. While this type of device is effective for removal of markings, it often creates excessive heat which may melt thermoplastic materials and cause equipment to gum up.
[0007] Another approach to pavement marking removal is the use of diamond saw blades or cutters arranged to make a dado cut. Still other types of machines use grinders or shot blast as described in U.S. Pat. Nos. 4,753,052; 4,376,358; 3,900,969; 4,336,671; 3,977,128 and 4,377,924. Unfortunately, these devices must remove a portion of the pavement material to effectively remove the marking, thereby leaving unsightly and potentially dangerous grooves in the pavement.
[0008] It is also known in the art to utilize high-pressure water jets to remove markings from pavement. NLB Corporation markets a high pressure water jet system for removing paint from pavement under the name “STARJET”. The STARJET system includes a blast head frame mounted on an attachment to the front bumper of a prime-mover truck. Casters support the frame for movement over the pavement and the path of the blast head is controlled by the driver steering the truck. Because of the position of the driver and the cab body of the prime-mover, it is difficult for the operator to see the blast head's position with regard to the stripes on the pavement. Obtaining clear vision requires the driver to lean out of the driver's side window, resulting in fatigue and other non-ergonomically efficient factors. Positioning the blast head to the passenger side of the prime mover is performed manually with some difficulty complicating the driver's ability to view the path of the blast head. In addition, due to the length of the extension holding the blast head, the angular off-set, and the swivel of the casters, the movement of the wheel of the truck is not directly related to the path of the blast head further complicating operation.
[0009] NLB Corporation also has another system marketed under the name “STRIPEJET”, that is a self-propelled tractor with a blast head mounted on the front of the tractor. A problem associated with the STRIPEJET device relates to the construction of the blast head mounting assembly. The mounting assembly includes a rigid track mounted transversely across the front of the tractor. A hydraulic cylinder is utilized to slide the blast head transversely across the rigid track to position the blast head. The construction limits visibility of the blast head to the operator. In addition, the construction prohibits the blast head from being positioned beyond the sides of the tractor. Still yet, the NLB construction only permits the blast head to be raised eighteen inches above the ground surface. This does not permit the operator to inspect the rotating assembly and/or nozzles of the blast assembly without exiting the vehicle and laying on the ground to look up into the blast head assembly.
[0010] Therefore, what is needed in the art is an articulating arm for a marking removal system. The articulating arm should permit movement of a blast head about a plurality of axes. The plurality of axis should permit the blast head to be easily aligned with the mark(s) to be removed from inside the vehicle. The arm should permit the blast head(s) to be positioned beyond the width of the vehicle to allow operation from a single road lane. The arm should articulate to a position that allows the inspection of the blast head from inside of the vehicle. The arm should facilitate mounting of multiple blast heads upon a single arm. Articulation of the arm should permit the blast heads to be oriented side by side, spaced along parallel paths, and one behind the other for increased efficiency in marking removal.
SUMMARY OF THE PRESENT INVENTION
[0011] Briefly, disclosed is an articulable arm particularly suited for mobile systems utilized to remove markings and/or coatings from surfaces with high pressure liquid. The mobile systems generally employ a liquid reservoir connected to a high pressure pump for directing ultra high pressure water through a blast head mounted on a front portion of the vehicle. A vacuum reservoir and vacuum pump are utilized to recover the water and debris from the surface. The arm permits an operator to easily maintain alignment of the blast heads to the surface markings being removed. After marking removal, the arm permits the blast heads to be raised to a position suitable for vehicle transport.
[0012] The base of the articulable arm is preferably mounted at about the center of the front portion of the truck. The articulable arm includes a primary extension assembly and a secondary extension assembly connected with a first transitional link assembly, at the distal end of the secondary extension assembly is a second transitional link assembly. Each component of the arm is independently positionable by an operator from within the vehicle. Mounted to the second transitional link assembly is one or more, preferably two, blast heads; the two blast heads positioned in a spaced apart arrangement along an axis that extends perpendicular to the longitudinal axis of the secondary extension assembly. This construction permits an operator to position each blast head over a separate surface marking, e.g. stripe or the like, to remove the two markings simultaneously. Rotation of the secondary extension assembly allows the operator to position the blast heads along juxtapositioned paths for creating a single, wide cleaning path. Alternatively, the secondary extension assembly may be rotated to position the blast heads one behind the other for dual cleaning of a single path.
[0013] In addition to allowing the blast heads to be raised for transport, the secondary extension assembly facilitates raising the blast head(s) to a position which allows the operator to inspect the water blast head assembly from within the cab of the truck.
[0014] Therefore, it is an objective of this invention to provide an articulable arm for surface marking removal systems.
[0015] It is another objective of the instant invention to provide an articulable arm that includes a water blast head for marking removal.
[0016] It is a further objective of the instant invention to provide an articulable arm that includes two water blast heads to allow multiple configurations of marking removal.
[0017] It is yet a further objective of the instant invention to provide an articulable arm that includes a primary extension assembly and a secondary extension assembly, each of which is independently controllable by an operator.
[0018] It is still another objective of the instant invention to provide an articulable arm having sufficient length to extend beyond the sides of the vehicle to which it is attached.
[0019] Still yet another objective of the instant invention is to provide an articulable arm which facilitates raising the blast head(s) to a position suitable to allow an operator to inspect the blast head(s) from within the vehicle.
[0020] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated from the following detailed description, taken in conjunction with the drawings, in which:
[0022] FIG. 1 is a perspective view of one embodiment of the instant invention illustrated with a single blast head in an operating position;
[0023] FIG. 2 is an exploded perspective view illustrating one embodiment of the articulable arm of the instant invention;
[0024] FIG. 3 is a side view illustrating one embodiment of the instant invention;
[0025] FIG. 4 is a top view illustrating one embodiment of the instant invention;
[0026] FIG. 5 is a perspective view of one embodiment of the instant invention illustrated without the actuators for clarity;
[0027] FIG. 6 is a perspective view of one embodiment of the instant invention illustrated without the actuators for clarity;
[0028] FIG. 7 is a top view of one embodiment of the instant invention illustrating the blast heads positioned in a spaced parallel relationship;
[0029] FIG. 8 is a top view of one embodiment of the instant invention illustrating the blast heads positioned for juxtaposed cleaning paths;
[0030] FIG. 9 is a top view of one embodiment of the instant invention illustrating the blast heads positioned for overlapping coverage of the marked surface;
[0031] FIG. 10 is a perspective view illustrating a blast head suitable for use with the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring generally to FIGS. 1-10 , an articulable arm 100 for use in removing markings from a marked surface is illustrated. The articulable arm is constructed and arranged to be infinitely positioned relative to the front portion 11 of a mobile vehicle 13 in a manner that allows the arm to extend beyond the sides of the vehicle if desired. A joystick or other suitable control device (not shown) is provided in the mobile vehicle to allow an operator to manipulate the articulable arm about the various axes for an operator determined path.
[0033] The articulable arm includes a base member 10 securable to a mobile marking removal vehicle. The mobile marking removal vehicle is preferably a truck, as illustrated in FIG. 1 . However, tractors, heavy equipment and the like may be utilized without departing from the scope of the invention. In a most preferred embodiment, the base anchor plate 12 is secured to a central location on a front portion of the vehicle for easy viewing of the assembly by an operator. At least two stanchions 14 are suitably secured to the base plate at about a perpendicular angle thereto. The stanchions are provided with an aperture 16 or other suitable means for securement of a first end 17 of a primary extension assembly actuator 18 . The stanchions are also provided with apertures 26 that define a first axis of rotation 28 .
[0034] A primary extension assembly 20 includes a first end 22 and a second end 24 . The first end of the primary extension assembly is pivotally secured to the stanchions 14 of the base member 10 via pin 30 for controlled movement about the first axis 28 . A primary actuator 18 having a first end 17 secured to the base member 10 and a second end 32 secured to the first end 22 of the primary extension assembly provides infinitely positionable controlled rotatation of the primary extension assembly throughout a curved horizontal path.
[0035] A first transitional link assembly 34 includes a first end 36 and a second end 38 , the first end being pivotally secured to the second end 24 of the primary extension assembly via pin 40 for controlled horizontal movement about second axis 42 . A secondary extension assembly actuator 60 having a first end 62 secured to the primary extension assembly 20 via stanchions 64 , and a second end 66 secured to the first end 36 of the first transitional link assembly 34 provides controlled rotational movement of the secondary extension assembly 44 about second axis 42 . In this manner, selective operation of the secondary actuator provides infinitely positionable control of the second end 48 of the secondary extension assembly 44 throughout a curved horizontal path. The first transitional link assembly 34 includes a toggle link assembly 76 , the toggle link assembly includes a pair of arctuate members 78 each having a first end 80 pivotally connected to the first transitional link assembly 34 and a second end 82 pivotally connected to a first end 84 of a substantially straight member 86 . A second end 88 of the straight member 86 is pivotally connected to tabs 90 secured to the secondary extension assembly 44 . In a most preferred embodiment, the straight member includes a plurality of apertures 92 therethrough for pivotal connection to the first end 70 of said third actuator 68 .
[0036] A secondary extension assembly 44 includes a pair of arms 45 , each having a first end 46 and a second end 48 . The first end of each arm is pivotally secured to the second end 38 of the transitional link assembly 34 for controlled vertical movement about a pair of parallel third axes 50 so that the arms 45 remain substantially parallel when moved through a vertical path. A third actuator 68 having a first end 70 secured to the second end 38 of the first transitional link assembly 34 and a second end 72 secured to the secondary extension assembly tabs 74 provides controlled rotation of the secondary extension assembly 44 about the third axes 50 . In this manner, selective operation of the third actuator 68 provides infinitely positionable control of the second end 48 of the secondary extension assembly 44 throughout a curved vertical path.
[0037] A second transitional link assembly 52 includes a first end 54 and a second end 56 . The first end 54 is pivotally secured to the second end 48 of the secondary extension assembly via pins 57 for controlled movement about a pair of fourth axes 58 . The second end 56 of the second transitional link assembly 52 is secured to at least one blast head assembly 54 ( FIG. 10 ). The second transitional link assembly 52 includes two mounting plates 94 secured in a substantially parallel arrangement with respect to each other and said second axis 42 . In this manner, the mounting plates 94 remain substantially parallel to the second axis irrespective of the position of said primary extension assembly 20 and/or the secondary extension assembly 44 . Thus the blasting heads 54 may be secured directly to the mounting plates for maintaining parallel alignment to the ground surface regardless of the position of the arms, as illustrated in Fig.5 . Alternatively, a pivot assembly 96 may be utilized to automatically rotate the blast head(s) 54 to a position that allows an underside of the blast head(s) to be viewed from an operator position when the secondary extension assembly 44 is raised to an uppermost position, as shown in FIG. 6 . The pivot assembly includes a pair of generally L-shaped brackets 98 , one pivotally secured to each of the mounting plates 94 . Each of the L-shaped brackets includes a generally vertical first leg 102 and a generally horizontal second leg 104 . The first legs include a tie rod 106 having a first end 108 pivotally secured thereto, a second end 110 being pivotally secured to the secondary extension assembly 44 . The second leg of the L-shaped brackets are constructed and arranged for securing at least one and preferably two blast heads thereto. In this manner, vertical movement of the secondary extension assembly 44 to an uppermost position causes rotation of the L-shaped brackets, as shown in FIG. 6 , to a position that allows an underside of the blast head(s) to be viewed from an operator position.
[0038] The second transitional link assembly may also include a means for rotating two blast heads about a sixth axis 114 extending substantially perpendicular with respect to the fourth axes 58 . The meas for rotating the blast heads about a sixth axis is illustrated herein as a rotation assembly 112 . The rotation assembly preferably utilizes an actuator to provide operator controlled rotation however, cables belts or suitable combinations thereof may be utilized without departing from the scope of the invention. In this manner, the two blast heads may be oriented side by side, spaced along parallel paths, or one behind the other for marking removal.
[0039] Referring to FIGS. 7-9 , the two blast heads 54 are spaced apart and positioned along a fifth axis 116 extending substantially parallel with respect to said fourth axes 58 . This configuration of the articulable arm is especially useful for marking removal. The positioning of the blast heads at the distal end of the articulable arm allows the blast head positioning and orientation to be controlled for optimum marking removal. For example, selective positioning of the secondary extension assembly 44 allows the two blast heads 54 to be positioned over two spaced surface markings 118 for simultaneous removal. In addition, selective positioning of the secondary extension assembly 44 also allows the two blast heads 54 to be positioned for juxtaposed cleaning paths, as illustrated in FIG. 8 . Still yet, selective positioning of the secondary extension assembly 44 allows the two blast heads 54 to be positioned one behind the other for overlapping coverage of the marked surface, as illustrated in FIG. 9 .
[0040] Referring to FIG. 10 , a blast head 54 suitable for use with the instant invention is illustrated. The blast head is carried on a chassis 120 supported on casters 122 . A shroud 124 descends from the chassis and surrounds a rotating spray head (not shown) that includes a plurality of high pressure nozzles. The spray head is connected to a high pressure fluid pump (not shown) by suitable means such as a high pressure hose. The shroud 124 is connected to a vacuum tank (not shown) by suitable means such as a vacuum hose (not shown).
[0041] It should be noted that while the preferred embodiment of the instant invention utilizes hydraulic actuators for controlled movement of the various components pneumatics, servos, electric motors or suitable combinations thereof may be utilized without departing from the scope of the invention.
[0042] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0043] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to, what is shown and described in the specification and any drawings/figures included herein.
[0044] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims. | Briefly, disclosed is an articulable arm particularly suited for mobile systems utilized to remove coatings from marked surfaces with high pressure liquid. The mobile systems generally employ a liquid reservoir connected to a high pressure pump for directing ultra high pressure water through at least one blast head mounted on a front portion of a mobile self-propelled vehicle. A vacuum reservoir and vacuum pump may be utilized to recover the water and debris from the surface. The arm permits an operator to easily maintain alignment of the blast heads to the surface markings being removed. After marking removal the arm permits the blast heads to be raised to position suitable for inspection and/or vehicle transport. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims priority to German Patent Application No. 10 2008 060 725.8, filed Dec. 5, 2008, entitled “Load Suspension Stand and Microscopy System,” the contents of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] A conventional stand comprises a plurality of components or stand members articulating in pairs, whereby a base stand member is supported by an object like, for instance, a flooring or a wall, and a load is suspended by a final stand member. By shifting the stand members relative to each other using the links joining them, it is possible to shift the load with respect to the object.
[0003] One example for such a stand is represented by a stand of a microscopy system carrying a load in the form of a microscopy optic. Such a microscopy system can be used for surgical interventions, whereby the microscopy optic is suspended by the stand such that a surgeon can shift it relative to a patient practically without exerting any force, i.e. by applying only minor actuating forces. This requires that the torsional moments exerted on the stand members by the weight of the microscopy optic and the weight of the stand members themselves are, as far as possible, compensated by the stand in all possible swiveling positions of the stand members relative to each other. The stand should further be adapted to support different microscopy optics differing from each other with respect to its weight and its center of mass position. Attaching additional components like a camera or additional eyepieces may, for example, modify the weight and the center of mass of a microscopy optic. To allow a compensation of the torsional moments exerted on the stand members independent of the swiveling positions, the stand has to be adjusted to such modifications.
[0004] Examples of such stands are, for instance, known from DE 42 45 034 C2, DE 42 31 516 C2, EP 1 205 703 B1, EP 1 312 850 B1, U.S. Pat. No. 6,523,796 B2, and WO 2007/054327 A1.
[0005] It has been found that conventional stands are inadequate for an adaptation to modified load situations practically independent of the swiveling positions.
SUMMARY OF THE INVENTION
[0006] The present invention has been accomplished taking the above problems into consideration.
[0007] According to embodiments of the present invention, a load suspension stand provides possibilities for an adaptation to different load situations.
[0008] According to further embodiments of the present invention, a microscopy system provides options for modifying a microscopy optic.
[0009] According to embodiments, a load suspension stand comprises at least a first component, a second component, a swivel joint linking the first to the second component, and a structure for providing a torsional moment at the joint between the two components. According to embodiments of the present invention, the structure is configured such that the torsional moment provided is modified subject to the swiveling position of the two components with respect to each other.
[0010] According to embodiments, the structure is further configured to enable a modification of the characteristic with which the torsional moment provided varies subject to the swiveling position using a drive. The drive may comprise an actuator, such as a motor. The drive may be configured for manual operation and comprise a manually operable rotary knob for that purpose.
[0011] According to embodiments, the structure comprises a cam plate rotatably fixed to the first component, and a load transmission lever being supported by the second component and configured to exert a force onto the cam plate. The force acting on the cam plate results in a torsional moment between the two components, whereby it is possible to adjust a desired characteristic of the torsional moment subject to the swiveling position of the two components relative to each other by a suitable configuration of the cam plate.
[0012] According to an embodiment, the structure for providing the torsional moment comprises a cam plate being rotatably fixed to the first component of the stand, a load transmission lever, an abutment for a swiveling support of the load transmission lever on the second component of the stand, and a load reservoir acting on the second component and on the load transmission lever, in order to have the load transmission lever exert a force on the cam plate.
[0013] According to embodiments of this, the load reservoir comprises a spring, like, for instance, a helical spring, a leaf spring or a gas pressure spring. In order to provide the required load, the spring can be biased in a compressed or in an expanded way.
[0014] According to embodiments, the abutment for a swiveling support of the load transmission lever on the second component can be shifted, relative to the load transmission lever, by a drive enabling a modification of the position on the load transmission lever effective for supporting the load transmission lever relative to the second component. This allows modification of the lever action for transmitting the load provided by the load reservoir to the load transmission lever, which results in a modification of the force induced from the load provided by the load reservoir that is acting on the cam plate.
[0015] According to embodiments herein, the load transmission lever can exert the force directly onto the cam plate, whereby the load transmission lever may provide options for reducing the friction force between the load transmission lever and the cam plate. These options may, for instance, comprise a roller being rotatably mounted on the load transmission lever or a provision of friction reducing surfaces on the load transmission lever, like, for instance, sliding faces of synthetic material.
[0016] According to further embodiments, the load is transmitted indirectly from the load transmission lever to the cam plate by disposing, for instance, a further swiveling intermediate lever in the line of force from the load transmission lever to the cam plate.
[0017] According to embodiments, the force transmitted from the load transmission lever onto the cam plate acts on a periphery of the cam plate. The cam plate is then configured such that a distance or a radius of the cam plate between its center and its periphery varies in the circumferential direction around the cam plate. According to alternative embodiments herein, the cam plate may further provide an inside circumferential surface on which a force directed radially outwards from the centre of the cam plate acts to generate the required swiveling position dependent torsional moment.
[0018] According to embodiments, the abutment supporting the load transmission lever comprises a roller having the load transmission lever abutted against its outside periphery. According to an embodiment herein, the drive comprises a slide being displaced relative to the second component and being also abutted against the outer periphery of the roller.
[0019] According to embodiments, the roller can be provided with cogs on its outer periphery and both the slide and the load transmission lever may be configured with a cog rail for engaging with the cogs of the roller.
[0020] According to further embodiments, a microscopy system is provided comprising a stand according to the previously described embodiments and a load formed by a microscope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The forgoing as well as other advantageous features of the invention will be more apparent from the following detailed description of exemplary embodiments of the invention with reference to the accompanying drawings, wherein
[0022] FIG. 1 shows a schematic representation of an embodiment a microscopy system,
[0023] FIG. 2 shows an elevational view of a portion of an embodiment of a stand, and
[0024] FIG. 3 shows a sectional view of the portion of the stand shown in FIG. 2 along the section line II-II shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0025] In the exemplary embodiments described below, components that are alike in function and structure are designated as far as possible by alike reference numerals. Therefore, to understand the features of the individual components of a specific embodiment, the descriptions of other embodiments and of the summary of the invention should be referred to.
[0026] Embodiments of a stand and of a microscopy system comprising a stand are explained below in relation to FIGS. 1 to 3 .
[0027] A microscopy system 1 as shown schematically in a perspective view in FIG. 1 comprises a microscope 3 mounted on a stand 5 . The stand 5 comprises a base 9 provided with wheels 7 to form a base portion of the stand. The base 9 supports a stand member 13 by means of a swivel joint 11 so that the stand member 13 can be pivoted around a pivoting axis 15 extending vertically into space. A further stand member 17 is mounted on the stand member 13 by means of a joint 19 such that it can be swiveled around a horizontal swiveling axis 21 . A further stand member 23 is in turn mounted on the stand member 17 by means of a joint 25 so that it can be pivoted around a horizontal pivoting axis 27 . A further stand member 29 is in turn mounted on the stand member 23 by means of a joint 31 so that it can be pivoted around a horizontal pivot axis 33 . The stand member 29 in turn supports a stand member 35 by means of a joint 37 so that it can be pivoted around a pivot axis 39 . A further stand member 41 is in turn articulated to the stand member 35 by means of a joint 43 so that it can be pivoted around a pivot axis 45 , and finally a chassis 47 of the microscope is articulated to the stand member 41 serving as the final stand member of the stand 5 by means of a joint 49 so that it can be pivoted around a pivot axis 51 . This allows a shifting of the microscope 3 within an available space and an alignment of its orientation in space by swiveling the stand members around the pivot axes.
[0028] Two counterweights 18 of the stand 5 are configured to substantially balance the microscope 3 with respect to the swiveling axes 21 and 27 , so that a user only has to overcome the residual friction force when swiveling the stand around these axes. Also for swiveling around a vertically aligned pivot axis 15 , a user only has to overcome the residual friction force.
[0029] The weight of the microscopy optic 3 and the weight of the stand member 41 generate a torsional moment around the swiveling axis 45 that acts on the stand member 35 via joint 43 . The torsional moment depends on a swiveling position between the two stand members 35 and 41 . A structure, which is explained below in more detail with respect to FIGS. 2 and 3 , for compensating for this torsional moment is provided on the stand members 35 and 41 .
[0030] The two stand members 35 and 41 can be swiveled relative to each other around the pivot axis 45 , with the corresponding joint comprising a shaft 51 aligned coaxially to the axis 45 and rotatably fixed to the stand member 35 and pivot-mounted with respect to the stand member 41 . Limbs 53 and 54 arranged with a clearance between them and forming part of a U-profile 55 are interspersed with a shaft 51 . Stand member 41 is fixed to limb 54 of the U-profile 55 , and the U-profile 55 comprises a base plate 56 from which the two limbs 53 and 54 protrude in a perpendicular direction. A cam plate is located in the centre between the two limbs 53 and 54 and affixed to the shaft 51 in a rotationally fixed manner. The cam plate 57 has an outside circumferential surface 58 which distance r to the pivot axis 45 varies in the circumferential direction. In FIG. 3 two distances r 1 and r 2 are shown as an example for different circumferential directions, whereby the directions of the two distances differ by an angle α of more than 20°, and whereby the ratio of r 2 to r 1 is more than 1.1.
[0031] A roller 61 abuts against the outer periphery 58 of the cam plate 57 with a force F 1 such that, because of the configuration of the circumferential surface 58 , a torsional moment D acts on the shaft 51 around the axis 45 . The roller 61 is mounted rotatably around an axis 67 by means of a shaft 66 and between a pair of intermediate levers 63 and 64 . The two intermediate levers 63 and 64 can in turn be pivoted around a pivot axis 69 by means of a shaft 70 mounted on the limbs 53 and 54 , whereby the shaft 70 is on both sides fixed to the limbs 53 and 54 of the U-profile 55 . The two intermediate levers 63 and 64 jointly carry a pin 71 extending in parallel to the pivot axis 69 between the two intermediate levers 63 and 64 . A load transmission lever 73 , abutted against a slide 77 by means of a roller 75 serving as an abutment, pushes against the pin 71 with a force F 2 . A pin 79 further pushes against the load transmission lever 73 with a force F 3 . The force F 3 is provided by a spring 81 , which abuts against a cover plate 83 fixedly attached to the limbs 53 and 54 of the U-profile 55 , and against a spring receptacle 85 coupled to pin 79 . The load transmission lever 73 transforms the force F 3 provided by spring 81 in to force F 2 , mainly in the ratio of the lengths l 1 to l 2 , with length l 1 corresponding to the distance between pin 79 and the position at which the load transmission lever 73 abuts against the roller 75 , and with length l 2 corresponding to the distance between pin 71 and the position at which the load transmission lever 73 abuts against roller 75 . Intermediate lever 63 in turn translates the force F 2 into force F 1 pushing against the periphery 58 of the cam plate 51 and according to the ratio of the lengths l 3 and l 4 , whereby length l 3 corresponds to the distance between pin 71 and the pivot axis 69 of the intermediate lever 73 , and the length l 4 corresponds to the distance between the pivot axis 69 and the rotary axis 67 of roller 61 .
[0032] Slide 77 abuts against the base 56 of the U-profile 55 by means of rollers 89 accommodated in a cage 87 such that the slide 77 can be shifted back and forth along a direction 91 and such that the forces F 3 and F 2 exerted by roller 75 on slide 77 are transferred by the rollers 89 onto the U-profile 55 .
[0033] A drive 93 is provided for displacing the slide 77 in direction 91 , the drive comprising a motor 95 with a cog 97 mounted on its driven shaft 96 engaging into a cog wheel 98 for driving a shaft 99 mounted in a bearing block 101 . The shaft 99 extends into a recess 103 formed in slide 77 . Recess 103 is provided with a female thread engaging with a male thread 105 provided on shaft 99 for transforming a rotational movement of shaft 99 in a linear displacement of a slide 77 along direction 91 . The displacement of slide 77 along direction 91 results in a rotation of the roller 75 around its axis, thereby displacing it relative to the load transmission lever 73 . By displacing the roller 75 relative to the load transmission lever 73 , both lengths l 1 and l 2 vary and thus also the ratio with which force F 3 provided by spring 81 is transmitted into force F 2 , which is in turn transmitted by intermediate levers 63 and 64 into force F 1 acting on cam plate 57 . Force F 1 can therefore be characterized by:
[0000]
F
1
=
l
3
l
4
×
l
1
l
2
×
c
×
Δ
S
,
[0000] whereby c represents the spring rate of spring 81 , and ΔS represents the length of the biased springs 81 .
[0034] Since the relation l 1 to l 2 , as well as the spring rate c of the spring, are factors in the above equation, the roller or abutment 75 , the slide 77 and its drive 93 thus combine to form a drive for varying the effective spring rate of spring 81 . The product c×l 1 /l 2 can therefore be interpreted as the spring rate of spring 81 effective at the periphery 58 of cam plate 57 . An operation of motor 83 therefore results in a variation of the effective spring rate, which could otherwise only be achieved by replacing spring 81 with a stronger or weaker spring.
[0035] The structure explained with reference to FIGS. 2 and 3 can therefore be used effectively for operatively compensating the torsional moments generated by microscopy optic 3 and stand member 41 which acts on the pivot axis 45 . The structure can in particular be used to compensate for variations of the microscopy optics 3 centre of mass using motor 95 .
[0036] For achieving a precise displacement of roller 75 relative to the load transmission lever 73 , roller 75 is formed by a cog wheel with cogs 105 formed at its periphery, whereby the slide 77 and the load transmission lever 73 comprise corresponding cog rails with cogs 106 and 107 adapted to engage with cog wheel 75 .
[0037] In the embodiment described above, the load transmission lever 73 transmits the force provided by springs 81 first to the intermediate levers 63 and 64 , which eventually transmit the force to the cam plate 57 . It is, however, possible to omit the intermediate levers so that the load transmission lever 73 transmits the force directly to the cam plate.
[0038] The structure for providing a variable torsional moment as explained with reference to FIGS. 2 and 3 is provided between the stand members 35 and 41 of a microscopy system according to an exemplary embodiment as explained with reference to FIG. 1 . However, it is appreciated that a respective structure can also be provided between other stand members.
[0039] The present invention has been described by way of exemplary embodiments to which it is not limited. Variations and modifications will occur to those skilled in the art without departing from the scope of the present invention as recited in the appended claims and equivalents thereof. | A load suspension stand includes a first stand member, a second stand member, a joint pivotably connecting the first with the second stand member, a cam plate rotatably fixed to the first stand member, a load transmission lever, an abutment pivotably supporting the load transmission lever at the second stand member, a load reservoir, acting on the second stand member and on the load transmission lever in order to exert a force F 1 on the cam plate by means of the load transmission lever, and a drive for displacing the abutment relative to the load transmission lever. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under Title 35 United States Code §119(e) of U.S. Provisional Application No. 60/721,922 filed Sep. 28, 2005, the full disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to systems and methods for flaw detection in physical structures, especially high value asset structures. The present invention relates more specifically to systems and methods for flaw detection and monitoring at elevated temperatures with wireless communication using surface embedded, monolithically integrated, thin-film, magnetically actuated sensors, and additionally to methods for fabricating sensors used in such systems.
2. Description of the Related Art
High quality, robust sensors capable of on-board detection and monitoring of damage would result in significant enhancements to the safety, reliability, and availability of high value assets, while minimizing their total life cycle costs. For highly stressed, fatigue-critical components, such as rotating components in turbines and rotorcraft, one would ideally like to obtain a direct measure of the state of damage in the material. However, obtaining such a measurement presents numerous technical challenges arising from the thermal and stress environments, combined with the high rotational speed and limited accessibility of such systems. Consequently, it is not surprising that there are presently no operational sensors for direct measurement of material damage (cracking) during component operation.
Attempts have also been made to use acoustic emission (AE) sensors to extract cracking signatures from the numerous sources of acoustic activity that accompany component operation. Although vibration and AE measurements are relatively easy to make, analyzing the results in order to extract the cracking signature from the overall rotor dynamics, or the acoustic background, continues to be a significant challenge.
A variety of nondestructive evaluation (NDE) techniques have been developed and refined for measurement of cracks to relatively small sizes (0.020 in.-0.030 in.) in depot based inspections. However, these techniques require component disassembly and a relatively well controlled environment; consequently they are not adaptable to on-line sensing in the operating environment. The development paradigm for such depot NDE techniques is very different from that needed to develop functional on-board sensors. Traditional depot-type inspections are driven by economics, which dictate that they be done relatively infrequently, and thus with high sensitivity, to ensure that damage (cracks) are small so that the component can survive until the next inspection, which is often ten years or more in the future.
The science and technology of prognosis and structural health management offer the potential for significant enhancements in the safety, reliability and readiness of high-value assets. For the case of turbine engines, this concept is based on a closed-loop process whose successful implementation depends on the integration of several multidisciplinary elements including: 1) onboard sensing of operational parameters and material damage states; 2) diagnosing trends, fault conditions, and underlying damage; 3) prognosing (predicting) remaining useful life in terms of probability of failure and limits on reliable performance, and 4) deciding upon appropriate courses of action. For example, whether or not the asset is capable of performing a given mission, or alternatively, is in need of inspection, maintenance, or replacement. As indicated, a wide variety of hardware and software tools are needed to facilitate these process steps. However, considerable uncertainty exists in the usage and sensor inputs, as well as the required modeling and associated materials property inputs. Consequently, there is an inherent need for the reasoning element of the prognosis system to be probabilistically-based.
Complementing the variety of onboard sensors are traditional health monitoring software tools for pattern recognition, neural networks, Bayesian updating, expert systems, and fuzzy logic. The advantage of these tools is that, when properly applied, they are highly efficient and thus amenable to onboard monitoring and real-time data interpretation. However, the disadvantage of these tools is that they rarely involve consideration of the underlying physical processes. Consequently, they require considerable empirical calibration or “training” for each specific application of interest. In contrast, probabilistic life prediction is typically based on materials property data, finite element thermal and stress analysis, pre-service inspection and in-service monitoring for defects, and damage accumulation algorithms. The advantage of this approach is that it is more amenable to linkage with the underlying physical mechanisms of damage (i.e., crack nucleation and growth). Thus, the process is inherently suitable for extension into materials prognosis, a concept that combines information on the material damage state with mechanistically-based predictive models.
The fundamental goal of all of these approaches is to facilitate better-informed decisions, whether for mission planning in the field (over the short term), or sustainment at the depot (over the longer term). In fact, the optimum prognosis system is likely to be some combination of traditional data-driven methods and probabilistic mechanics methods. Thus, in many respects the above tools can be viewed as being complementary.
With regard to on-board crack detection in fatigue-critical components, the important question becomes: What detection sensitivity is sufficient to provide the desired component reliability, provided essentially continuous inspections can be conducted, either during or after each operation cycle? Studies have been carried out involving, for example, probabilistic simulation of low-cycle fatigue crack initiation and growth at a bolt hole of a typical compressor disc in a military turbine engine. Predicted probabilities of failure over the life of the disc have been evaluated for various inspection scenarios ranging from no inspections to continual inspections with varying sensitivities. The probability of failure under such conditions begins to increase first for the case where no inspection is performed. In contrast, inspections performed continually (i.e. once every flight) result in markedly lower probability of failure even with relatively coarse inspection sensitivities of 200 to 300 mils (in size). For these cases, acceptable probabilities of failure are maintained by inspecting on each flight and removing defective discs from service. The results obtained under these studies show that sensitivities of 200 to 300 mils can be effective for on-board monitoring for cases where critical crack sizes exceed these values. Continual monitoring with sensitivities 10 times lower than those typically employed in depot inspections (20-30 mils) are effective because of the trade-off between inspection sensitivity and inspection frequency. In other words, on-board inspections do not require high sensitivity to be effective because they only need to find cracks that will not grow to failure in the next few flights. Similar benefits of continual on-board monitoring are anticipated for fatigue critical components, although specific results will obviously depend on the critical crack size in the component, and thus will be component dependent.
It would therefore be desirable to have a system (and a method of operating the system) that is capable of on-board detection and monitoring of cracks in critical structures with a sensitivity that is commensurate with the frequency of interrogation made possible by the system. It would be desirable for such a system to utilize a sensor structure that is robust enough to withstand the vibrational and thermal extremes typically experienced within such high-value asset systems (such as turbines and rotors). It would therefore be desirable to include wireless connectivity to and from the sensor structure(s) that could operate within the high level EM noise environment of rotating metal components. It would further be desirable to provide a versatile sensor manufacturing process that could create customized sensors suitable for specific structural systems and specific operating environments.
SUMMARY OF THE INVENTION
One embodiment (that forms the basis of the present invention) for using embedded sensors in association with a system for monitoring a turbine engine disc is illustrated in FIG. 1 . The system as generally shown includes a plurality of sensors 30 (as described in greater detail below) that are placed (for example) near fracture critical components such as turbine blades 22 and turbine discs 24 . These sensors 30 positioned on the moving components 12 of turbine engine 10 are in wireless RF signal connection to a receiving antenna 14 positioned on a stationary component of engine 10 . Antenna 14 is connected through a signal line 16 to data processing instrumentation 20 for signal analysis. This concept includes distributed thin-film magnetostrictive sensors that are integrated onto the component surface near fracture critical locations (FCLs). Periodically activating the thin-film sensors by generating ultrasonic waves enables interrogation of the material component for defects through the detection of reflected waves from the defect using the “pulse-echo” mode of detection. The complete sensor system concept also includes a fully integrated antenna for the harvesting of energy using microwaves (or other frequency electromagnetic waves) thereby providing power for sensor activation and radio frequency (RF) communication of the backscattered ultrasonic signals. This fully integrated, monolithic, wireless, self-powered crack detection sensor provides effective structural health management and prognosis in turbine engines, as well as other high-value assets.
A thin-film sensor form factor offers unique advantages over other detector architectures in terms of performance and integration simplicity (a relatively simple architecture for monolithic surface integration), mass-production compatibility to micro-system manufacturing processes, and durability under the severe challenges posed by high-temperature operating environments. In theory, several thin-film materials and associated physical phenomenon are possible including magnetostrictive (Ms), piezoelectric, or shape memory, all of which can be deposited as thin films. However, magnetostrictive thin films are seen as providing one of the best modes for structuring a sensor for use in the system of the present invention since they offer several attractive features: a) a high energy output for remote-control actuation and communication, b) a wide range of candidate material systems (and associated process flexibility to meet end-use requirements), and c) inherent durability and robustness.
Significant enhancements in the reliability and readiness of high-value assets are achievable by implementing prognosis systems such as described by the present invention. This real time, or near-real time, decision making process is based on the acquisition and fusion of on-line sensor feedback, combined with physics-based analytical models for damage accumulation, and higher order reasoning for decision making.
The present invention therefore provides: (1) a monolithically integrated, multi-layered (nano-composite), thin-film sensor structure that incorporates a thin-film, multi-layer magnetostrictive element, a thin-film electrically insulating or dielectric layer, and a thin-film activating layer such as a planar coil; (2) a method for manufacturing the multi-layered, thin-film sensor structure as described above, utilizing a variety of factors that allow for optimization of sensor characteristics for application to specific structures and in specific environments; (3) a system and a method integrating the multi-layered, thin-film sensor structure as described above, and further utilizing wireless connectivity to the sensor mounted on moving components within the monitored assembly.
The method for manufacturing the engineered, monolithically integrated, multi-layered (nano-composite), thin-film structure includes a number of customizing factors including the magnetron sputtering (or vapor deposition) of alternating layers of a high (hard) magnetostrictive material (iron/rare earth or similar alloy) and a high magnetization (soft) material (FeCo or similar) directly onto sensing platform or onto a flexible backing substrate that can later be affixed to sensing platform. Composite magnetostrictive layer properties, such as magnetostriction coefficient, saturation magnetization, and Curie temperature (thermal stability), can be engineered by adjusting layer thicknesses (2 nm-50 nm), soft/hard layer ratio (typically greater than 1) and sputtering deposition parameters (with and without ion assist and/or RF sample bias) with minimum total layered composite thickness such that losses due to skin depth effects are minimized (typically greater than 3 microns). Composite magnetostrictive layers can also be post-annealed in a magnetic bias field or annealed in-situ as part of elevated temperature service to enhance performance.
The dielectric layer may be composed of a number of different materials, such as oxides, nitrides, carbides, or others, to be deposited over top of the composite layer using reactive magnetron sputtering (or other compatible methods) to serve as an electrically insulating layer and for resistance to high temperature oxidizing environments, again with thicknesses generally not to exceed 3 microns.
The activation layer may preferably comprise a conductive planar antenna coil, to be deposited through shadow mask techniques directly on top of the dielectric layer.
In addition, the method of manufacturing may include steps in which the surface of the sensing platform is treated chemically, thermally, or mechanically (or coated with an adhesion promoter layer) to optimize impedance and mechanical adhesion of the composite magnetostrictive film at elevated temperatures. As a result, the monolithically integrated sensor may be applied to different types of sensing platforms (other engineering metals, composites, etc.) or applied to flexible (or thin) film supports which are then bonded to the engineering platform.
A further important aspect of the manufacturing process may include steps in which the magnetic spin orientation is engineered, thereby eliminating the need for magnetic biasing with permanent magnets prior to activation, or during operation. The manufacturing method may also include steps in which the dielectric layer and activation layer are deposited by methods other than magnetron sputtering, such as other PVD, wet chemical, or plasma/flame spray techniques. Other types of magnetostrictive materials (other than iron-based) may also be substituted to achieve specific properties or enhance actuation performance.
The monolithically integrated sensor manufactured as described above may further be utilized for applications other than flaw detection, such as temperature, strain, and other structural/material phenomena measurable through signal modification. The thin-film sensor, consisting of multiple layers, that is magnetostrictive when used with an RF excitation, can produce ultrasonic waves (guided as well as bulk) in the monitored material and can operate at temperatures as high as 1200° F.
The methods of employing wireless communication techniques allow the system to transmit the data acquired by the thin-film multi-layer sensor to a receiver antenna near or within the component under interrogation. These methods include passive wireless communication of a response signal from the magnetostrictive sensor. The wireless connectivity design of the system may further include an RF backscatter modulator circuit with high fidelity for communicating analog response signals from the magnetostrictive sensor. Finally, the wireless connectivity feature of the system of the present invention may include the coupling of RF signals from an antenna on a stationary component of the assembly being investigated, to an RF backscatter modulator on the rotating component of the assembly.
Variations on the above described systems, sensors, and methods that fall within the scope of the present invention will become apparent to those skilled in the art from the following descriptions and disclosures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional schematic diagram of the wireless thin-film magnetostrictive sensing approach implemented by the systems and methods of the present invention.
FIG. 2 is a schematic perspective view of a basic system for carrying out the magnetostrictive sensing of material defects.
FIG. 3 is a partial cross-sectional view of the thin-film sensor of the present invention, including the planar coil component of the sensor.
FIGS. 4A-4C are graphic representations of the spin orientations in the FeCo/FeTb multi-layer structure.
FIGS. 5A & 5B are graphs of normalized magnetostriction vs. normalized magnetization for in-plane ( FIG. 5A ) and perpendicular ( FIG. 5B ) anisotropy.
FIG. 6 is a graph of magnetostriction vs. terbium content for different deposition methods.
FIGS. 7A-7C are graphs of signal defect detection using the multi-layered thin-film sensor over a range of temperatures.
FIG. 8 is a graphic plot of the signal to noise ratio for variations in the defect cross-sectional area using the sensor of the present invention showing the sensitivity of the multi-layered thin-film sensors.
FIG. 9 is a bar chart showing the de-bond strength of a 4 μm FeCo thin-film sensor structure as a function of film processing steps.
FIG. 10 is a logarithmic plot showing the de-lamination strengths of 4 μm FeCo thin-film during first half-cycle (monotonic loading) and after 10 5 fatigue cycles.
FIG. 11 is a logarithmic plot showing a comparison of FeCo thin-film de-lamination strengths with Ti-6Al-4V (a conventional fine grain titanium alloy) fatigue strengths at various load ratios.
FIG. 12 is a logarithmic plot showing a comparison of fatigue strengths of Ti-6Al-4V with and without 3-4 μm thin-films.
FIG. 13 is a graphic plot of strain signals from thin-film structures during fatigue testing to 100,000 cycles at maximum applied stresses of 79 ksi (top curve), 65 ksi (middle curve), and 55 ksi (bottom curve) (ksi=thousands of pounds per square inch).
FIG. 14 is a perspective view of an open split turbine casing showing a patch communications tag positioned on the rim region of the 7 th stage compressor disc of a turbine engine.
FIG. 15 is a polar coordinate plot of return levels (above noise floor) from a wireless backscatter communication tag with various types of antennae.
FIG. 16 is a graph of the input signal vs. the output signal for various antennae arrangements showing the wireless backscatter communications dynamic ranges for each.
FIGS. 17A & 17B are signal graphs showing a magnetostrictive sensor (MsS) waveform communicated wirelessly via backscatter link.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Probabilistic Analysis of Prognosis Uncertainty (Preliminary Discussion)
Probabilistic analyses (detailed in the above referenced Provisional Patent Application, the disclosure of which has been incorporated herein by reference) suggests that continual monitoring of with sensors that are 6 to 10 times less sensitive than those presently used in depot inspections (about 30 mils) can achieve high component reliability (low probabilities of failure). This benefit results from the continual feedback that enables damaged components to be identified and removed from service throughout their life. Although this concept of trading-off interrogation sensitivity for frequency of interrogation is believed to be generally true, the specific minimum sensitivities required for effective onboard sensing will depend on the critical crack size associated with the specific fatigue critical location. That is, for the specific case of a bolt-hole in a generic disc, for example, the critical crack size may be greater than 300 mils; thus sensors with 200 mil to 300 mil sensitivity would be able to detect and signal the removal of cracks before they became critical. However, in general there may exist fatigue critical locations in fracture-critical components that have critical crack sizes less than 300 mils, in which case the onboard sensor would need to have greater sensitivity than 300 mils.
The Overall System: Multi-Layer Thin-Film Sensor with Induction Coil, Wireless Sensor Excitation/Activation, Wireless Sensor Signal Transmission, Remote Receiver & Signal Processor
The basic physics by which magnetostrictive sensing occurs is schematically illustrated in FIG. 2 . Four basic components are required: 1) an induction coil 48 for transduction of an electric current into a magnetic flux, 2) a ferromagnetic strip 46 for transduction of the magnetic flux into a displacement based on the magnetostrictive effect, 3) a fixed magnetic field to enhance the efficiency of energy transduction process (not shown), and 4) associated power amplification and signal conditioning (not shown). In this manner, fatigue cracks 42 in a material structure 40 under investigation, may be detected by means of sensing the return elastic waves with the magnetostrictive sensor (combination of 46 & 48 ).
To effectively detect surface and sub-surface fatigue damage non-destructively, a sensor must be in intimate contact with the material surface, and therefore able to withstand the harsh thermal and stress environment that exists within the engine. Thin-film sensor architecture, with negligible mass, provides a minimally intrusive means of measuring surface/bulk parameters as it can be vacuum-deposited directly onto the surface. Fatigue cracking would be monitored via injection and scattering of elastic waves from defects and results would be communicated wirelessly to overcome the inaccessibility problem.
Injection and corresponding detection of scattered elastic waves is accomplished through the conversion of electrical to mechanical and mechanical to electrical energies. For the current sensor concept, these changes could theoretically be transduced into electrical energy using materials with magnetostrictive (Ms), piezoelectric, or shape memory effects; all of which can be deposited as thin films. In comparison to other thin film, ‘smart’ materials, magnetostrictive thin films offer several attractive features: a) a high energy output for remote-control actuation and communication, b) a wide range of candidate material systems—and associated process flexibility to meet end-use requirements, and c) inherent durability and robustness.
The thin film, multi-layer, architectural design for the Magnetostrictive Sensor (MsS) consists of a magnetostrictive (Ms) layer (e.g., FeCo, FeTb, or others), a transduction coil for activation/sensing, with conducting antenna patch/dielectric layers and on-board power management devices for wireless communication. To further increase response sensitivity, increase the high temperature stability, and reduce the necessary driving current for magnetic saturation (i.e., magnetic susceptibility), Ms layers are constructed as thin multi-layer(s) of magnetostrictive amorphous alloys (e.g., FeTb, etc.) in combination with magnetically soft (high magnetization) alloys (i.e., FeCo, etc.). Since all of the components can, in principle, be engineered into a thin-film architecture, and since thin-film Ms materials have already been demonstrated in remote actuator (bimorph resonators and optical scanners) and sensor applications, important factors include: 1) optimizing these materials for non-invasive operation at high temperatures (mechanical compliance, chemical inter-diffusion, etc.), 2) reducing the necessary driving fields for remote actuation/communication, and 3) orientation of in-plane magnetic-easy axis with respect to driving magnetic field(s). Results show the improvement in magnetic properties as the selection of material and architecture of the film is evolved from a single layer of nickel to a multi-layer composite film of Fe/FeTb. It is important to note that for magnetostrictive activation, the ideal magnetic response should have low coercive force, x-intercept of forward scan, high slope (permeability), and high magnetic saturation (maximum induced field on y-axis). This type of magnetic behavior will typically result in a high output response (voltage amplitude) in a pitch-catch mode of operation. An example of a less than ideal case is the as-deposited nickel film. An initially deposited 3 μm-thick pure nickel film not only exhibits a high coercive force (32 Oe), but poor permeability as well (a stepped curve due to anomalous striped domain formation). Hence, the signal (voltage) response for these single layer films was comparatively low.
In comparison to pure nickel films, alloy films have been shown to exhibit superior magnetic characteristics. For example, the magnetic response of a representative FeCo alloy exhibits a much more favorable in-plane anisotropy with high permeability in comparison to pure nickel; however, the coercive field (>40 Oe) is of the same magnitude as nickel. Hence, the overall signal actuation response is similar to that of pure nickel films. However, the addition of vanadium to FeCo and the use of a “seed” layer of Ta or Cu, results in a considerable reduction in the coercive force (from >40 Oe to <3 Oe).
Composite, Multi-layer Thin-Film Development
As described above, the use of alternating layers of a high magnetization (soft) layer of FeCo, and a high magnetostrictive layer of FeTb, not only enhances the efficiency of the magnetoelastic response but also improves the interface stability at high temperatures by minimizing the driving force for nucleation and subsequent interdiffusion. An example of the improved thermal stability of the “engineered” multi-layer configuration is shown in FIG. 11 where the coercive field was reduced to less than 10 Oe for a FeCo/FeTb multi-layer stack. The multi-layer film was then annealed at 250° C. for more than 4 hours and the stability of the film was verified using x-ray reflection measurements; the periodic peaks are caused by reflections from the layered structure and the constancy of the response before and after the anneal demonstrates the stability of the stack.
Generation and Detection of Guided Waves with Thin-Films
Guided waves are mechanical, or elastic, waves in ultrasonic and sonic frequencies that propagate in a bounded medium, such as a pipe, plate, or shell, parallel to the plane of its boundary. The wave is termed “guided” because it travels along the medium guided by the geometric boundaries of the medium and the geometry has a strong influence on the behavior of the wave. In contrast to ultrasonic waves used in conventional ultrasonic inspections that propagate with a constant velocity, the velocity of guided waves varies significantly with wave frequency and geometry of the medium. This is referred to as dispersion. In addition, at a given wave frequency, the guided waves can propagate in different wave modes and orders. Although the properties of guided waves are complex, with judicious selection and proper control of wave mode and frequency, the guided waves can be used to achieve volumetric inspection of a large area of a structure from a single sensor location. One judicious approach is to choose a mode that does not have significant dispersion in the frequency range of interest. In the current work, the horizontally polarized shear wave mode is chosen because it is basically non-dispersive. This means that the wave travels in the material under inspection at a constant velocity.
Guided waves can be generated by using piezoelectric or magnetostrictive sources. Piezoelectric sources cannot be used at high temperatures (i.e. above about 200° F.). In contrast magnetostrictive sources can work at temperatures close to their Curie temperatures (in certain instances as high as 1200° F.). The magnetostrictive sensor generates and detects guided waves. For wave generation, it relies on the magnetostrictive (or Joule) effect; the manifestation of a small change in the physical dimensions of ferromagnetic materials—on the order of several parts per million in carbon steel—caused by an externally applied magnetic field. For wave detection, it relies on the inverse-magnetostrictive (or Villari) effect which is a change in the magnetic induction of ferromagnetic material caused by mechanical stress (or strain).
As discussed above, the Curie temperature can often be increased as the material moves from the bulk form to an engineered thin film. Previous work has utilized nickel foil (on the order of 125 microns thick), which has a Curie temperature of approximately 600° F.
Data on initial films that were 3 to 12 microns thick has demonstrated that guided waves could be generated. These indications were determined from data collected from thin films applied to titanium plate using the pitch-catch mode. The source in this instance is a 125-micron nickel foil and the thin-films are used as receivers. Tests have been run with a 12-micron thin film nickel on a ½ inch thick titanium plate, 7-micron thick films on ⅛ inch and ½ inch thick titanium plate, and a 3-micron thick thin film on a ⅛ inch and ½ inch plate. Even though these thin films were not optimized, the evidence shows that thin films can detect guided waves. This type of data has been observed for frequencies ranging from 250 KHz to 1000 KHz.
The Sensor Structure
A primary component of the system of the present invention is the multi-layered thin-film sensing material. As illustrated in FIGS. 3 & 4 , this multi-layered thin-film consists of alternating FeCo (crystalline iron cobalt) 62 and FeTb (amorphous iron terbium) 64 layers, which are each nominally 10 nm thick. FIGS. 4A-4C are graphic representations of the spin orientations in the FeCo/FeTb multi-layer structure where FeCo (iron cobalt) is the “soft” layer 62 and FeTb (iron terbium) is the “hard” layer 64 . FIGS. 4A-4C show; (A) anti-parallel and in-plane 66 & 68 , (B) parallel and in-plane 70 & 72 , and (C) in and out-of-plane orientations 74 & 76 . Typically 320 individual layers (see 60 in FIG. 3 ) are deposited giving a total film 52 thicknesses in the range of 3-4 μm. An oxide layer (Al 2 O 3 ) 54 is also deposited on top of the nano-layered thin-film 52 to provide protection from the operating environment as well electrical insulation for the metallic coil 56 which is positioned on top of the oxide layer 54 as shown, and provides the electrical-to-magnetic transduction. This multi-layered, thin-film architecture has been demonstrated to provide numerous benefits: 1) high actuation efficiency and low power requirements for wireless activation and communication, 2) achievement of low mass, low profile by eliminating the use of a bulky permanent magnet magnetic biasing, and 3) thermal stability at elevated temperature by eliminating re-crystallization and suppressing diffusion.
The multi-layer magnetostrictive thin-film sensor of the present invention consists of a soft magnetization layer (i.e., FeCo with high saturation magnetization) in combination with a hard magnetization layer (i.e., FeTb with high magnetostriction); for the purpose of establishing a nano-composite film with high magnetostriction at low actuation (driving) B-fields (soft behavior). Performance is related to individual film thickness which in turn is related to the “ferromagnetic exchange length”. In other words, at thicknesses below the exchange length, domain wall formation is suppressed and actuation occurs at the magnetic spin (moment) level (an average of the two individual layer properties). Although layers typically couple anti-parallel at these length scales, overall magnetization is set by the thickness ratio, that is, as a function of increasing thickness of the soft magnetic layer (with constant hard layer thickness), saturation magnetization, Ms, for anti-parallel coupling first decreases and then increases up to a value nearly equal to the case for parallel coupling.
If the individual layer thickness is increased above the minimum for domain wall formation, the magnetic polarization curve exhibits a 2-stage response (a different slope in the low field and high field regions) with the soft magnetic layer responding in the low field region and the hard magnetic layer responding at higher fields. To show the feasibility of the present invention layer thicknesses between 3 to 15 nm were investigated, although evidence has shown that with thicknesses up to 25 nm a corresponding onset of 2-stage behavior occurs. For individual layer thicknesses less than approximately 3 nm-5 nm, there is evidence to indicate the properties of the diffuse interphase region can begin to control magnetic coupling and subsequently, overall performance of the structure.
Although a low magnetic saturation field is desirable (i.e., low coercive field and high permeability), the evidence has not yet shown how layer thickness (for a constant ratio below the domain wall width) in a composite, multi-layer structure affects coercive force, H c , and magnetic saturation field, H s , since to a first order, spin orientation is assumed to be fairly uniform within an individual layer, whether it be the soft FeCo or hard FeTb layer. In other words FeCo, with its high magnetization, provides the high saturation magnetization and soft magnetic response whereas the FeTb, with its high magnetostriction, provides the gain to the actuation response. Management of spin orientation within the individual layer of a composite structure, however, is important to overall multi-layer performance. In particular, spin orientation with respect to the plane of the film and the applied magnetic field directly affects the overall output response of a multi-layer magnetostrictive film and is directly affected by each of the processing parameters discussed in more detail below.
The Sensor Method of Manufacture
It is first important to characterize the concept of spin orientations within a multi-layer structure and its affect on actuation response. The first factor to consider is the ease of movement or rotation of the spin and is typically characterized by the magnetic polarization loop. In general, a low coercive field, H c , in combination with a low magnetic saturation field, H s , is indicative of low anisotropy with spins orienting easily and rapidly along the applied magnetic field direction. Spins that rotate easily, although crucial to insuring low magnetic actuation fields, do not necessarily correspond to maximum displacement. The key is the initial orientation of the spins within the multi-layer structure as the initial orientation of spins, not only have a direct impact on the output strain or displacement of the film, but the resulting remnant or retentive field within the structure as well; i.e., the response to a fixed magnetic bias field. In applications where a permanent magnet cannot be used to pre-align spins, it would be desirable to have a film that could establish a preferential orientation to the spins that maximizes strain (displacement) under an applied field.
In general, for positive magnetostrictive materials (FeCo and FeTb), induced tensile stresses promote in-plane spin orientations (distribution) within a thin film whereas compressive stresses promote out-of-plane spins or spins perpendicular to the plane of the film. Since in most thin-film actuator applications, the applied magnetic field is in the plane of the film, the approach is to create spins that are not only in the plane of the film but perpendicular to the applied field. For a typical multi-layer film with anti-parallel coupling, the spin orientation (designated by arrows 66 & 68 ) would appear as in FIG. 4A for each of the individual layers 62 & 64 . Depending on processing parameters, spins could also be oriented in-plane and parallel (shown in FIG. 4B ) as well as a mixture of in-plane and out-of-plane orientations (shown in FIG. 4C ).
Magnetic anisotropy is typically produced through a dipole-dipole interaction and the local crystalline-electric-field gradient through spin-orbit coupling. As a consequence of a higher density of neighboring atomic distribution in the film plane, i.e. dense films with compressive stresses, the electron angular momentum tends to be aligned perpendicular to the plane and therefore magnetization perpendicular to the plane. With respect to maximizing the change in magnetostriction or displacement, orientation of the magnetic field with respect to the distribution of spin orientations is critical. For example, a magnetization process only caused by motion of 180° spins cannot lead to any magnetostriction. In cases shown in FIGS. 4A & 4B above for in-plane spins, if the spins and the magnetic field are oriented as shown in the plane of the page without any orientation out of the page, then there would be very little magnetostriction. In this case, there is some in-plane anisotropy and these types of films would exhibit high magnetostriction at low fields due to easy rotation of spins in the isotropic plane even though the 180° spins don't contribute much to magnetostriction. According to sources in the prior art, the motion of 180° domain walls leads to a magnetization of M max /2 without any magnetostriction. Ideally a magnetization process due to motion of 90° spins (oriented into or out of the page for shown in FIGS. 4A & 4B ) will induce a larger change in magnetostriction with easy rotation of spins. In contrast, films with perpendicular anisotropy, such as shown in FIG. 4C , require higher applied fields in order to obtain the same in-plane magnetization and magnetostriction although the overall magnetostriction would be higher than in shown in FIGS. 4A & 4B . Predicted responses for in-plane and out-of-plane magnetostriction are shown in FIGS. 5A & 5B respectively.
Thin films of amorphous FeTb prepared by most vapor deposition methods possess a strong intrinsic uni-axial magnetic anisotropy perpendicular to the film plane reflecting some sort of anisotropy built in during the growth process; i.e., presumably at the local cluster level (thermal, strain, etc.). This uni-axial anisotropy varies with FeTb composition, peaking at a concentration of around 26-28 atomic percent and then decreasing in a predictable linear fashion at concentrations above 35%. Some variation in easy axis orientation occurs as the concentration is varied above and below 22 atomic percent Tb. At Tb concentrations greater than approximately 32%, magnetostriction increases and then peaks at a concentration around 42% for DC magnetron sputtered films with an applied in-plane magnetic field as shown in FIG. 6 . (It is important to note that the prior art shows that zero magnetostriction occurs for Tb concentrations less than 32% in DC magnetron sputtered films). Evaporated and RF sputtered FeTb films exhibit a much broader magnetostrictive response as a function of composition with reasonable responses below 30% Tb.
In summary, a structure that facilitates easy spin rotation would yield a quick (movement at high frequency) response at low magnetization fields; anisotropy would tend to be low in this type of situation and therefore a magnetic bias field would be required to induce preferential alignment prior to actuation. In contrast, a structure that has higher anisotropy in the hard layer, in particular spins oriented perpendicular to the plane of the film (case (c) above) would require higher overall activation fields although the overall actuation may be greater and the higher anisotropy would tend to preferentially orient spins without the need for a magnetic bias field.
Based on the above strategy, FeTb/FeCo multi-layers can be produced from compound and tiled targets using dual DC magnetron sputter sources. The specific process parameters (independent variables) used to fabricate these films are as follows:
RF Bias
Source Power Settings (Power/Voltage)
Thickness (individual layer, total number of layers, ratio, etc.)
Layer composition
Surface pre-treatment (ion clean, “seed” layer, etc.)
Sputter/Base Pressure (throttle position and gas flow)
Substrate-to-source distance, Angle-of-incidence
Magnetic Bias
Substrate Temperature
The present invention therefore addresses a method for manufacturing an engineered, monolithically integrated, multi-layered (nano-composite), thin-film structure for flaw detection and monitoring, which consists of a thin-film multi-layer magnetostrictive layer, a thin-film electrically insulating or dielectric layer, and a thin-film activating layer, such as a planar coil, that includes: (a) magnetron sputtering of alternating layers of a high (hard) magnetostrictive material (iron/rare earth or similar alloy) and a high magnetization (soft) material (FeCo or similar) directly onto sensing platform or onto flexible backing substrate that can later be affixed to sensing platform, (b) composite magnetostrictive layer properties, such as magnetostriction coefficient, saturation magnetization, and Curie temperature (thermal stability), that are engineered by adjusting layer thickness (2-50 nm), soft/hard layer ratio (typically greater than 1) and sputtering deposition parameters (with and without ion assist and/or RF sample bias) with minimum total layered composite thickness such that losses due to skin depth effects are minimized (typically greater than 3 microns), (c) composite magnetostrictive layers that are post-annealed in a magnetic bias field or annealed in-situ as part of elevated temperature service to enhance performance, (d) a dielectric layer, such as oxide, nitride, carbide, or other, deposited over top of the composite layer using reactive magnetron sputtering (or other compatible method) to serve as electrically insulating layer and for resistance to high temperature oxidizing environments; thickness not to exceed 3 microns, and (e) an activation layer, such as conductive planar antenna coil, deposited through shadow mask directly on top of dielectric layer.
In addition, the method above may include a step where the surface of the sensing platform is treated chemically, thermally, or mechanically (or coated with adhesion promoter layer) to optimize impedance and mechanical adhesion of composite magnetostrictive film at elevated temperatures. The method may also include a step where the monolithically integrated sensor is applied to different types of sensing platforms (other engineering metals, composites, etc.) or applied to flexible (or thin) film support which is then bonded to engineering platform.
The method of the present invention may also include a step where a magnetic spin orientation is engineered as part of the manufacturing process thereby eliminating the need for magnetic biasing with permanent magnets prior to activation, or during operation. Further, the method may include a step where the dielectric layer and activation layer are deposited by methods other than magnetron sputtering, such as other PVD, wet chemical, or plasma/flame spray techniques.
The method may also use other types of magnetostrictive materials (other than iron-based) to achieve specific properties or enhance actuation performance. The method may also be applied where the monolithically integrated sensor is used for other applications than flaw detection, such as temperature, strain, and other.
The Sensor Robustness
Film magnetostrictive performance and durability were optimized by following the above strategy and through manipulation of the above processing parameters based on feedback from measured magnetization (magnetic polarization), magnetostriction, mechanical stress, thermal stability and de-lamination strength. The application of the resulting films to defect detection over a range of temperatures and stresses is described below.
FIGS. 7A-7C show the signals obtained from a 4 μm-thick, 320 layer FeCo/FeTb film as a function of temperature. All data were obtained with the sensor deposited near the end of a 2 in.×8 in.×0.125 in. aluminum alloy plate containing a 0.060 in.×0.4 in. notch defect located about 4 in. from the sensor. The saturated signals to the left in these figures correspond to the initial activation of the sensor and the reflection from the near edge of the plate, while the large signals in the right of these figures are the reflections from the far edge of the plate. The smaller signals in the middle of these figures (circled as 100 , 102 & 104 ), at about 4 in. on the horizontal scale, are reflections from the defect. As can be seen the defect signal is clearly evident and is about 10 times the background noise level in all cases. The fact that the amplitude of the signal does not diminish upon increasing the temperature from 120° F. to 550° F. attests to the stability of the film over this temperature range.
In addition, films were exposed to temperatures of 550° F. for hundreds of hours without observable changes in magnetization (B-H) curves, and X-ray reflections.
It is also interesting to note that the position of each reflection in FIGS. 7A-7C systematically shifts to the right with increasing temperature. This is due to the decrease in the velocity of the elastic (ultrasonic) wave propagation with increasing temperature. This temperature sensitivity results in a longer arrival time, which is interpreted as an apparent increase in distance of the reflectors from the thin film sensor when a constant velocity is assumed. This shift does not pose a problem for the monitoring of defects since it is the amplitude that is of primary interest to these measurements. This effect could also be compensated for in the signal processing by using the shift in reflections from fixed features (e.g., edges, holes) to estimate the temperature and correct for the change in wave propagation velocity. These results also demonstrate that the sensor is multifunctional and can be used to monitor temperature, as well as defects, in components.
Initial experiments to characterize the flaw size detection sensitivity of the thin film sensor have recently been performed. Surface-connected, notched flaws of increasing sizes from 5 mils deep by 30 mils long (5×30 mils) to 50 mils deep by 150 mils long were successively introduced into a 2 in.×8 in.×0.125 in. plate containing a multi-layered thin-film sensor at one end about 2 in. from the defects. Results are shown in FIG. 8 in terms of defect area versus signal-to-noise ratio (SNR). The two smallest areas near the detection limit corresponded to defect sizes of 5×30 mils and 10×30 mils and exhibited SNR values of 1.5 and 2.2, respectively. In contrast, the largest defect exhibited an SNR value of about 20. The results in FIG. 8 show that the sizes being detected are about ten times smaller in size than the target sensitivities that probabilistic computations have shown to be beneficial to component reliability.
In addition to temperature stability, it is important that sensors for on-board monitoring have adequate mechanically durable to withstand the stresses experienced by components in service. An assessment has been made of the durability of FeCo thin films on Ti-6Al-4V. As shown in FIG. 9 , the de-lamination strength of 4 μm thick FeCo films is a strong function of processing parameters. As can be seen from these results in this figure, de-lamination strength can be significantly increased (up to 5 times) by sputtering to remove nascent oxides from the substrate before depositing the film, as well as by producing slightly compressive stresses in the films.
The fatigue performance of the thin film is also of interest since many critical components are subjected to fatigue loading. FIG. 10 shows, again for a 4 μm-thick FeCo film on Ti-6Al-4V, that the fatigue strength of the film is essentially the same as the de-lamination strength (shown plotted at 1 cycle). These data indicate that the strength of the thin film is controlled by interface de-lamination and not by fatigue. This observation is not surprising since the grain sizes in the deposited thin films are typically less than 1 μm, and it is well known that fine grain size promotes high fatigue strengths.
FIG. 11 is a logarithmic plot showing a comparison of FeCo thin-film de-lamination strengths with Ti-6Al-4V (a conventional fine grain titanium alloy) fatigue strengths at various load ratios (R) obtained on notched specimens with an elastic stress concentration factor (k t ) of 2.4. The high de-bond strengths indicate that films can withstand typical low-cycle fatigue loading in compressor discs. FIG. 11 compares the two highest de-lamination/fatigue strengths with the fatigue strengths of notched Ti-6Al-4V coupons. As indicated, the strength of the film exceeds the strength of the Ti-6Al-4V in the fatigue regime of interest to turbine discs, which is beyond 10 5 cycles. It should be pointed out that the results in FIG. 12 are plotted in terms of the maximum nominal stress (not the concentrated stress at the notch) since the sensors would be located several inches or more away from the fatigue critical location in components and thus would not experience the concentrated stresses. Film de-bonding levels are shown for Comp. RS plus cleaning at 110 , and for simple Comp. RS at 112 .
The fatigue strength of the substrate in the presence of the thin film is also paramount importance, since the film deposition process must not degrade the durability of the underlying material/component. FIG. 12 is a logarithmic plot showing a comparison of fatigue strengths of Ti-6Al-4V with and without 3-4 μm thin-films. Invariance of the fatigue strength with and without the film demonstrates that the film deposition process is not detrimental to the titanium alloy substrate. FIG. 12 compares the fatigue strength (at about 10 5 cycles) of Ti-6-Al-4V bend specimens with and without thin films. These results are essentially indistinguishable. Baseline results generated on the same heat of materials using tension specimens are also shown for comparison. Although the latter comparison indicates higher fatigue strengths for the specimens with thin films, this difference is likely due to the well-known tendency for bend specimens to exhibit higher fatigue strengths than tensile specimens due to the stress gradient in the specimen. Nevertheless, the conclusion is that the FeCo thin films do not degrade the fatigue strength of the Ti-6-Al-4V substrate.
Fatigue experiments were also performed while monitoring the performance of the thin-film in the inverse mode. This mode is the inverse process from that described above for launching elastic waves to interrogate the material for damage. Specifically, the applied stress in the substrate caused a change in the magnetic flux in the film, which is in turn sensed by the coil as an electric current. In this mode, the film functions similar to a strain gage. However, the resulting voltage is due to the inverse magnetoelastic effect and not due to a resistance change as in conventional wire strain gages. The voltage outputs from the film are shown in FIG. 13 as a function of applied fatigue cycles at increasing levels of maximum applied stress. At low stress (55 ksi), the film response exhibits an initial transient before stabilizing for the remainder of the test to 10 5 cycles. At the intermediate stress (65 ksi), the response is initially similar to that at the lower stress but subsequently continues to increase slightly throughout the test. This increased output throughout the fatigue test is hypothesized to be due to the evolution of slip in selected grains that are favorably oriented with respect to the direction of applied stress. At the highest stress (79 ksi), de-lamination of the film was observed, and although the film continued to respond, the magnitude of the signal decreased throughout the experiment. The continued response of the film is due to the fact that de-bonding begins locally and propagates over increasing regions of the film. Thus, the film continues to respond but the signal strength decreases as less and less film is in intimate contact with the substrate. Two conclusions can be drawn; first, the magnetostrictive thin films can be employed to monitor strain—another indication of their multi-functionality, second, the films give clear indications of de-bonding by decreasing strain response. In this regard, the amplitude of reflected elastic waves from defects and interfaces has also been observed to decrease following the onset of de-bonding. These features can be used during data processing to identify a malfunctioning sensor. The inverse magnetoelastic response associated with changing stress in the component is not expected to alter the crack detection process since the mechanical loading occurs at much lower frequencies than the frequency (500 kHz to 1 MHz) used to interrogate the material.
The Wireless Signal Acquisition Methodology
The method of the present invention also involves the use of a wireless communication system that can be used to transmit the data acquired by the thin film multi-layer sensor to a receiver antenna near or within the component under interrogation. In addition, the method may employ passive wireless communication of the response signal from the magnetostrictive sensor.
The system of the present invention includes an RF backscatter modulator circuit with high fidelity for communicating analog response signals from a magnetostrictive sensor and employs a method for coupling RF signals from an antenna on a stationary component to an RF backscatter modulator on the rotating component.
To assess the feasibility of wireless communication with a thin-film magnetostrictive sensor within a rotating component (in this case, a turbine engine core), two types of experiments were performed. The first was designed to characterize the radio channel between the sensor, which would be deposited on the surfaces of the rotating engine discs, and an interrogating antenna located at one or more fixed positions within the engine casing. The second was designed to characterize the performance of radio backscatter technology, in particular signal dynamic range, which affects sensor sensitivity.
Both experiments utilized two different radio backscatter ID tags, which operate with an illumination signal of approximately 2.45 GHz and produce a modulation signal that is approximately 100 kHz offset from the illumination frequency. These tags were designed to be as simple as possible to facilitate their migration to a thin-film form factor to enable operation within the elevated temperature environment of turbine engines.
In the first set of experiments the two tag types were placed inside an enclosed section of a military engine core as is depicted in FIG. 14 and tag return signals were monitoring with an external antenna. One tag type incorporates a patch antenna (printed metallization on a circuit board) while the other is a dipole type with protruding wires. The patch tag is enclosed in a plastic disc case that is 2.2″ diameter and 0.33″ thick. This tag 130 was placed on the 7 th stage compressor disc 122 rim surface of a military engine above the seal as shown in FIG. 14 . The dipole tag is much smaller (1″×0.5″×0.2″ with dipole wires extending another 0.75″ on each side of the 1″ dimension), and was installed between two of the blades on the 8 th compressor stage 124 . In each case, the tags were taped into place to keep them from shifting during the course of measurements.
External antennas were configured for both radial and axial wireless access to the tags. For radial access, an existing 7/16″ diameter access port 126 located between the 7 th and 8 th stages 122 & 124 of the compressor was utilized. The external antenna for radial access consisted of a one-quarter-wavelength coaxial cable stub formed by simply stripping back the outer jacket and braided cable shield approximately 0.8″ from one end of a coaxial cable leaving just the center conductor and dielectric. The exposed stub end was covered with electrical tape to prevent shorting to the engine surfaces when inserted into the access port. Radial measurements were taken with the antenna probe inserted into the access port in two manners: 1) with it straight in, perpendicular to the casing wall, and 2) with it bent at right angle after insertion, running parallel to the casing wall. For axial access, a spiral cavity-backed antenna was positioned directly above the 4 th stage blades pointing downward toward the 5 th and subsequent stages.
Measurements of the tag return signal modulation level were taken at 30-degree increments clockwise around the full circle (12:00, 1:00, 2:00, etc) by manually rotating the bladed disc assembly. For example, at 12:00, the antenna is directly adjacent to tag, whereas at 1:00, the tag is rotated roughly 30 degrees clockwise with respect to antenna as viewed when facing the 4 th -stage compressor side of the engine.
The polar plots in FIG. 15 illustrate the azimuth responses for four different test cases as follows:
Test Case 1, “Stub-0”: Patch Tag, External Stub Antenna inserted into the radial access port with the Stub straight in line with the access port such that it runs perpendicular to the casing wall.
Test Case 2, “Stub-90”: Patch Tag, External Stub Antenna inserted into the radial access port with the Stub bent at right angle such that it runs parallel to the casing wall.
Test Case 3, “Dipole”: Dipole Tag, External Stub Antenna inserted into the radial access port with the stub bent at right angle such that it runs parallel to the casing wall.
Test Case 4, “Spiral”: Patch Tag, External Spiral Cavity-Backed Antenna positioned axially above the 4 th compressor stage facing downward toward subsequent stages.
The above results show that wireless communication is feasible within the complex geometry of the turbine engine core using radio backscatter tags located on the disc rim surfaces, blade attachment points, or blades, and an external antenna positioned radially between stages from the existing built-in access ports. Axial propagation across multiple stages is also feasible meaning that an access port is not required for each stage. Although the tags could not be read from some azimuth positions, this may be overcome by higher illumination power and/or selection of a different illumination frequency. The tags available for testing were only operable near 2.5 GHz, so other frequencies were not investigated at this time. From another perspective, less than 360-degree azimuth coverage could benefit the system by providing a means of separating responses from multiple sensors.
To characterize the dynamic range and fidelity of communication signals from these same radio backscatter ID tags, a test setup was configured in an RF anechoic chamber consisting of a modulation source, a backscatter tag (antenna plus modulator), a backscatter reader, a digitizing oscilloscope, and a spectrum analyzer. A modulation waveform is communicated over a 2.4 GHz radio backscatter link and recovered for display on the oscilloscope or spectrum analyzer. The backscatter tag was placed at a distance of two meters from the reader. The reader was operated with its antenna panel orthogonal to the floor and facing the tag.
For dynamic range characterization, the waveform generator was set to a 100 kHz sine wave signal. A variable 100-dB attenuator was inserted in series between the signal source and the tag in order to extend the amplitude range of the generator such that low drive levels could be reached. The spectrum analyzer was tuned to 100 kHz with a resolution bandwidth of 1 kHz and the observed signal power level was measured as a function of the drive level applied to the backscatter tag.
To assess communications performance, the waveform generator was loaded with digitally sampled data that was captured using typical magnetostrictive sensor (MsS) instrumentation. This waveform is an actual MsS signal that was obtained using an existing Ni-foil sensor that is representative of the type of signal that is anticipated for the thin-film sensor. It is the echo return signal from a nickel foil MsS probe, which has been stimulated by an inductively-coupled short pulse (i.e., a few cycles) of a 128 kHz sine wave. The waveform recovered via the backscatter link was observed on the digital oscilloscope and compared with the modulating signal.
A plot of modulator drive level (input) versus recovered signal level (output) is shown in FIG. 16 , illustrating the linearity or dynamic range of the backscatter communications channel. Separate plots are overlaid for direct comparison of the different backscatter tag antenna configurations that were tested (patch, horizontal dipole, vertical dipole). Tick marks are annotated on the plots to coincide with the minimum and maximum points that bound the linear range. The derivative (i.e., slope) of the output/input curve was taken to ascertain linearity. For this analysis, slope values within the range of 0.8 to 1.2 are considered to be effectively linear for the purpose of measuring the dynamic range. FIGS. 17A & 17B show that backscatter communications can achieve 50-60 dB of linear range. FIG. 17B is the detail section 140 of the plot shown in FIG. 17A . The patch type tag is linear from about 30 μV up to 30 mV of input drive, while the dipole type tag is linear from about 100 μV up to 50 mV.
FIG. 16 shows overlays of the MsS modulation signal (input) applied to the patch-type tag and the recovered MsS signal (output) via the backscatter link. The plots clearly show that the output signal tracks the modulation input very closely. Although plots are not shown, similar results were obtained with the MsS modulation signal applied to the dipole-type tag.
Based on these results, it is seen that a simple backscatter tag consisting of only one active element and a printed antenna can be used to communicate an analog information signal with 50-60 dB of linear dynamic range. From a qualitative perspective, this level of fidelity appears to be quite adequate for a typical MsS echo return signal. The corresponding drive signal required to modulate the backscatter tag in its linear operating range is on the order of 10's of μVs up to 10's of mV.
Although the present invention has been described in terms of the foregoing preferred embodiments, this description has been provided by way of explanation only, and is not intended to be construed as a limitation of the invention. Those skilled in the art will recognize modifications of the present invention that might accommodate specific environments. Such modifications as to size, and even configuration, where such modifications are merely coincidental, do not necessarily depart from the spirit and scope of the invention. | Systems and methods for flaw detection and monitoring at elevated temperatures with wireless communication using surface embedded, monolithically integrated, thin-film, magnetically actuated sensors, and methods for fabricating the sensors. The sensor is a monolithically integrated, multi-layered (nano-composite), thin-film sensor structure that incorporates a thin-film, multi-layer magnetostrictive element, a thin-film electrically insulating or dielectric layer, and a thin-film activating layer such as a planar coil. The method for manufacturing the multi-layered, thin-film sensor structure as described above, utilizes a variety of factors that allow for optimization of sensor characteristics for application to specific structures and in specific environments. The system and method integrating the multi-layered, thin-film sensor structure as described above, further utilizes wireless connectivity to the sensor to allow the sensor to be mounted on moving components within the monitored assembly. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to vitamin D compounds, and more particularly to 6-methylvitamin D 3 analogs and their pharmaceutical uses.
The most active metabolite of vitamin D 3 , 1α,25-dihydroxyvitamin D 3 is a potent calcium and phosphorous-regulating hormone playing an important role in bone homeostasis in animals and humans. Also, in addition to this classical role, the natural hormone elicits immunomodulation as well as cell differentiation and proliferation activities in numerous malignant cells and keratinocytes [Feldman et al, Vitamin D, 2 nd ed.; Elsevier Academic Press: New York, 2005]. 1α,25-Dihydroxyvitamin D 3 expresses these functions by binding to the vitamin D receptor (VDR), a ligand-regulated transcription factor. Structural analogs of this metabolite have been prepared and tested such as 1α-hydroxyvitamin D 3 , 1α-hydroxyvitamin D 2 , and various other side-chain and A-ring modified vitamins. Some potent synthetic analogs have been used clinically to treat bone disorders such as osteoporosis and the skin disorder—psoriasis. Some of these compounds exhibit separation of activities in cell differentiation and calcium regulation. The difference in activity may be advantageous in treating a variety of diseases such as renal osteodystrophy, vitamin D-resistant rickets, osteoporosis, psoriasis, and other malignancies.
Although more than 3000 synthetic analogs of the natural hormone have been obtained and tested to date, very few of them were characterized by substitution of the intercyclic C(5)=C(6)-C(7)=C(8) diene moiety. 6-Fluorovitamin D 3 was synthesized by Dauben et al. [J. Org. Chem. 50, 2007 (1985)] and this compound has been shown to antagonize 1α,25-(OH) 2 D 3 activity, especially intestinal calcium absorption, in vivo in chicken [Wilhelm et al., Arch. Biochem. Biophys. 233, 127 (1984)]. The synthesis of 6-methylvitamin D 3 was reported by Sheves and Mazur [J. Chem. Soc., Chem. Commun. 21 (1977)] using 6-oxo-3,5-cyclovitamin D precursor; the same compound was also obtained by Yamada et al. [Tetrahedron Letters 22, 3085 (1981)] by reductive thermal desulfonylation of the 6-methylated vitamin D 3 -sulfur dioxide adduct. Recently, 1α-hydroxy-6-methylvitamin D 3 was synthesized by a novel approach involving Pd-catalyzed carbocyclization—Negishi cross-coupling cascade [Reino et al., Org. Lett. 7, 5885 (2005)].
Compounds alkylated at C-6 seemed to be interesting targets for synthetic and biological studies. Such vitamin D analogs easily undergo thermal conversion to their previtamin forms. Moreover, the results of molecular modeling indicate that significant deviation from planarity must be present in their diene system, connecting the ring A to the C,D-hydrindane fragment. This is obviously associated with the interaction of the 6-alkyl substituent and hydrogens from the C-ring (at C-9). Such deviation from the planar geometry can be of importance when the vitamin D analog forms a complex with VDR. Recently, Moras et al. reported the X-ray crystal structure of the ligand binding domain (LBD) of the hVDR complexed with the native hormone [Moll. Cell, 5, 173 (2000)]. Later, many other crystal structures of the LBD-VDR bound to different vitamin D compounds were solved and it became clear that VDR binds (at least in the crystalline state) the vitamin D ligands having their intercyclic C(5)=C(6)-C(7)=C(8) diene moiety in the s-trans conformation, exhibiting a torsion angle of ca. −150°. Therefore, in a continuing effort to develop 1α,25-dihydroxyvitamin D 3 analogs with biological profiles suitable for pharmaceutical uses we have synthesized 6-methyl analog of 1α,25-dihydroxyvitamin D 3 .
SUMMARY OF THE INVENTION
The present invention is directed toward 6-methylvitaimn D 3 analogs, their biological activity, and various pharmaceutical uses for these compounds. These new vitamin D compounds not known heretofore are the vitamin D 3 analogs having a hydroxyl substituent at the carbon-1-position (C-1), a hydroxyl substituent attached to the 25-position (C-25) in the side chain, and a methyl group attached at the 6 position (C-6). The preferred vitamin D analog is 1α,25-dihydroxy-6-methylvitaimn D 3 (hereinafter referred to as “Me-Cvit”).
Structurally these 6-methylvitamin D 3 analogs are characterized by the general formula I shown below:
where X 1 , X 2 and X 3 , which may be the same or different, are each selected from hydrogen or a hydroxy-protecting group. The preferred analog is 1α,25-dihydroxy-6-methylvitamin D 3 which has the following formula Ia:
The above compounds I, particularly Ia, exhibit a desired, and highly advantageous, pattern of biological activity. These compounds are characterized by relatively high binding to vitamin D receptors, which is about the same as that of the native hormone 1α,25-dihydroxyvitamin D 3 . These compounds are less potent (about 2 logs) in causing cellular differentiation and are also less potent (about one log) in stimulating 24-OHase gene expression compared to 1,25(OH) 2 D 3 . These compounds also have less ability to promote intestinal calcium transport in vivo than 1,25(OH) 2 D 3 , especially at the recommended lower doses. They are greater than 1,000 times less potent than the native hormone, and thus would be classified as having lower activity and thus lower potency in vivo in stimulating intestinal calcium transport activity, as compared to that of 1α,25-dihydroxyvitamin D 3 . These compounds I, and particularly Ia, also have less ability to mobilize calcium from bone, and they are about 400 times less potent than the native hormone, and thus would be classified as having lower potency in vivo in bone calcium mobilizing activity as compared to 1α,25-dihydroxyvitamin D 3 .
The above compounds I, and particularly Ia, are characterized by relatively high cell differentiation activity and in promoting transcription of the 24-hydroxylase gene. Thus, because these compounds have cellular differentiation activity and are more potent than the native hormone in causing transcription, but are less potent in causing intestinal calcium transport, they have potential as an anti-cancer agent, especially for the prevention or treatment of leukemia, colon cancer, breast cancer, skin cancer and prostate cancer. Also, because compounds of formula I, and especially the compound Me-Cvit of formula Ia, bind to the Vitamin D receptor with the same affinity as the native hormone but has markedly lower potency in biological calcemic activities downstream from receptor binding, it is possible this compound could act as a dominant negative and be useful as an antidote for vitamin D intoxication, i.e. it may act in vivo as an antagonist against hypercalcemia caused by a vitamin D compound.
One or more of the compounds may be present in a composition to treat the above-noted diseases in an amount from about 0.01 μg/gm to about 1000 μg/gm of the composition, preferably from about 0.1 μg/gm to about 500 μg/gm of the composition, and may be administered topically, transdermally, orally, rectally, nasally, sublingually or parenterally in dosages of from about 0.01 μg/day to about 1000 μg/day, preferably from about 0.1 μg/day to about 500 μg/day.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIGS. 1-5 illustrate various biological activities of 1α,25-dihydroxy-6-methylvitamin D 3 , hereinafter referred to as “Me-Cvit”, as compared to the native hormone 1α,25-dihydroxyvitamin D 3 , hereinafter “1,25(OH) 2 D 3 .”
FIG. 1 is a graph illustrating the relative activity of Me-Cvit and 1,25(OH) 2 D 3 to compete for binding with [ 3 H]-1,25-(OH)-2-D 3 to the full-length recombinant rat vitamin D receptor;
FIG. 2 is a graph illustrating the percent HL-60 cell differentiation as a function of the concentration of Me-Cvit and 1,25(OH) 2 D 3 ;
FIG. 3 is a graph illustrating the in vitro transcription activity of 1,25(OH) 2 D 3 as compared to Me-Cvit;
FIG. 4 is a graph illustrating the bone calcium mobilization activity of 1,25(OH) 2 D 3 as compared to Me-Cvit in a group of animals; and
FIG. 5 is a graph illustrating the intestinal calcium transport activity of 1,25(OH) 2 D 3 as compared to Me-Cvit in a group of animals.
DETAILED DESCRIPTION OF THE INVENTION
1α,25-dihydroxy-6-methylvitamin D 3 (referred to herein as “Me-Cvit”) a vitamin D analog which is characterized by the presence of a methylene substituent at the carbon 1 (C-1), a hydroxyl substituent attached to the 25-position (C-25) in the side chain, and a methyl group attached at the 6 position (C-6), was synthesized and tested. Structurally, this vitamin D analog is characterized by the general formula Ia previously illustrated herein, and its pro-drug (in protected hydroxy form) is characterized by general formula I previously illustrated herein.
The preparation of 6-methylvitamin D 3 analogs having the structure I can be accomplished by a common general method, i.e. the coupling of a bicyclic vinyl bromide II, easily prepared from a Grundmann ketone III, with the acyclic unit, vinyl triflate IV, followed by deprotection at C-1, C-3 and C-25 in the latter compound to arrive at the compound Me-Cvit having the structure Ia (see Scheme 1 herein):
In the structures H, III and IV groups Y 1 , Y 2 and Y 3 are selected from the group consisting of hydrogen and a hydroxy-protecting group. The method shown above represents an application of a new, highly efficient convergent strategy in which ring A and the triene unit of the vitamin D compound are constructed by one-pot Pd-catalyzed tandem cyclization-Negishi coupling process. Such strategy has been applied effectively for the preparation of the 1α-hydroxyvitamin D 3 and 1α,25-dihydroxyvitamin D 3 [Reino et al., Org. Lett. 7, 5885 (2005)].
Hydrindanones of the general structure III are known, or can be prepared by known methods. Specific important example of such known bicyclic ketones is 25-hydroxy Grundmann's ketone [Baggiolini et al., J. Org. Chem., 51, 3098 (1986)]. Bromoolefines of the general structure II are known [for Y 3 =TES, see: Maeyama et al., Heterocycles 70, 295 (2006)] or can be prepared from III according to Trost procedure [J. Am. Chem. Soc. 114, 1924, 9836 (1992)].
Vinyl triflates of the general structure IV are known, or can be prepared by known methods [Reino et al., Org. Lett. 7, 5885 (2005)].
For the preparation of the required vitamin D compounds of general structure I, a synthetic route has been developed starting from the known alkenyl bromide 1 [Maeyama et al., Heterocycles 70, 295 (2006)] and the known vinyl triflate 2 [Reino et al., Org. Lett. 7, 5885 (2005)]. Process of their coupling and further transformation into the desired 1α,25-dihydroxy-6-methylvitamin D 3 is shown on the SCHEME I. Thus, metalation of the bromide 1 with tert-butyllithium and subsequent transmetalation with zinc bromide provided the intermediate organozinc derivative. To this derivative was added the vinyl triflate 2 together with triethylamine and a catalytic amount of tetrakis(triphenylphosphine)palladium(0). Removal of the silyl protecting groups in the obtained 6-methylvitamin 3 was performed in the acidic conditions using hydrofluoric acid-pyridine complex. The final 1α,25-dihydroxy-6-methylvitamin D 3 ( 4 ) was purified by HPLC. Although the vitamin 4 very easily isomerizes to its previtamin D form 5 , it can be stored by a prolonged time in a freezer.
As used in the description and in the claims, the term “hydroxy-protecting group” signifies any group commonly used for the temporary protection of hydroxy functions, such as for example, alkoxycarbonyl, acyl, alkylsilyl or alkylarylsilyl groups (hereinafter referred to simply as “silyl” groups), and alkoxyalkyl groups. Alkoxycarbonyl protecting groups are alkyl-O—CO— groupings such as methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, isopropoxycarbonyl, butoxycarbonyl, isobutoxycarbonyl, tert-butoxycarbonyl, benzyloxycarbonyl or allyloxycarbonyl. The term “acyl” signifies an alkanoyl group of 1 to 6 carbons, in all of its isomeric forms, or a carboxyalkanoyl group of 1 to 6 carbons, such as an oxalyl, malonyl, succinyl, glutaryl group, or an aromatic acyl group such as benzoyl, or a halo, nitro or alkyl substituted benzoyl group. The word “alkyl” as used in the description or the claims, denotes a straight-chain or branched alkyl radical of 1 to 10 carbons, in all its isomeric forms. “Alkoxy” refers to any alkyl radical which is attached by oxygen, i.e. a group represented by “alkyl-O.” Alkoxyalkyl protecting groups are groupings such as methoxymethyl, ethoxymethyl, methoxyethoxymethyl, or tetrahydrofuranyl and tetrahydropyranyl. Preferred silyl-protecting groups are trimethylsilyl, triethylsilyl, t-butyldimethylsilyl, dibutylmethylsilyl, diphenylmethylsilyl, phenyldimethylsilyl, diphenyl-t-butylsilyl and analogous alkylated silyl radicals. The term “aryl” specifies a phenyl-, or an alkyl-, nitro- or halo-substituted phenyl group.
A “protected hydroxy” group is a hydroxy group derivatised or protected by any of the above groups commonly used for the temporary or permanent protection of hydroxy functions, e.g. the silyl, alkoxyalkyl, acyl or alkoxycarbonyl groups, as previously defined. The terms “hydroxyalkyl”, “deuteroalkyl” and “fluoroalkyl” refer to an alkyl radical substituted by one or more hydroxy, deuterium or fluoro groups respectively. An “alkylidene” refers to a radical having the general formula C k H 2k — where k is an integer.
More specifically, reference should be made to the following illustrative example and description as well as to Scheme 1 herein for a detailed illustration of the preparation of compound Me-Cvit.
In this example specific products identified by Arabic numerals (1, 2, 3, etc.) refer to the specific structures so identified in the Scheme 1.
EXAMPLES
Chemistry. Ultraviolet (UV) absorption spectra were recorded with a Perkin-Elmer Lambda 313 UV-VIS spectrophotometer in ethanol. 1 H nuclear magnetic resonance (NMR) spectra were recorded in deuteriochloroform at 400 and 500 MHz with a Bruker DMX-400 and Bruker DMX-500 spectrometers, respectively. 13 C nuclear magnetic resonance (NMR) spectra were recorded at 100 and 125 MHz with the same spectrometers in deuteriochloroform. Chemical shifts (6) were reported downfield from internal Me 4 Si (δ 0.00). High-performance liquid chromatography (HPLC) was performed on a Waters Associates liquid chromatograph equipped with a Model 6000A solvent delivery system, a Model U6K Universal injector, and a Model 486 tunable absorbance detector. THF was freshly distilled before use from sodium benzophenone ketyl under argon.
Example 1
Preparation of 1α,25-dihydroxy-6-methylvitamin D 3 (4)
(a) Coupling of alkenyl bromide 1 with vinyl triflate 2 (SCHEME I). A solution of t-BuLi (1.55 M in pentane; 0.31 mL, 0.466 mmol) was added dropwise to a solution of vinyl bromide 1 (100 mg, 0.210 mmol) in anhydrous THF (2 mL) at −78° C. under argon. After 30 min, a solution of ZnBr 2 (0.48 M in THF; 0.53 mL, 0.252 mmol) was added. The reaction mixture was stirred at 0° C. for 1 h. After cooling to −40° C., a mixture of vinyl triflate 2 (90 mg, 0.146 mmol), Et 3 N (0.13 mL, 1.05 mmol) and (Ph 3 P) 4 Pd (14 mg, 0.012 mmol) in anhydrous THF (2 mL) was transferred via cannula. The mixture was stirred at room temperature for 14 h. Then it was quenched by addition of water, poured into saturated aqueous solution of NH 4 Cl and diluted with ether. Organic phase was dried (Na 2 SO 4 ) and concentrated. The residue was purified by flash chromatography on silica. Elution with hexane/Et 2 O (98:2) provided the crude product that was purified by HPLC (9.4 mm×25 cm Zorbax-Sil column, 4 mL/min) using hexane. The protected 6-methyl analog of the natural hormone (compound 3) was eluted at R V 15 mL (61 mg, 49%; 88% based on recovered substrate).
3: 1 H NMR (500 MHz, CDCl 3 ) δ 5.68 (1H, s, 7-H), 5.21 (1H, d, J=0.5 Hz, 19E-H), 4.79 (1H, d, J=1.6 Hz, 19Z-H), 4.54 (1H, dd, J=9.0 and 4.0 Hz, 1□-H), 4.32 (1H, br s, 3□-H), 2.55 (1H, m), 2.26 (1H, m), 1.90 (1H, m), 1.83 (3H, s, 6-CH 3 ), 1.19 (6H, s, 26- and 27-H 3 ), 1.06 (36H, 6×SiCH(CH 3 ) 2 ], 0.95 (9H, t, J=7.9 Hz, 3×SiCH 2 CH 3 ), 0.93 (3H, d, J=6.2 Hz, 21-H 3 ), 0.88 (6H, m, 6×SiCH(CH 3 ) 2 ), 0.56 (s, 3H, 18-H 3 ), 0.56 (6H, q, J=7.9 Hz, 3×SiCH 2 CH 3 ); 13 C NMR (125 MHz) δ 150.9 (s, C-10), 138.5 (s, C-8), 132.6 (s, C-5), 129.2 (s, C-6), 124.1 (d, C-7), 110.7 (t, C-19), 73.5 (s, C-25), 70.6 (d, C-1), 68.0 (d, C-3), 56.6 (d), 55.9 (d), 45.5 (t), 40.6 (t), 39.1 (t), 36.5 (t), 36.2 (d), 31.6 (t), 30.5 (t), 30.0 and 29.8 (2×q, C-26 and C-27), 27.7 (t), 25.3 (s), 23.5 (t), 22.7 (t), 22.5 (t), 20.9 (t), 20.3 (q, 6-CH 3 ), 18.8 (q, C-21), 18.27, 18.2, 18.18, 18.15, 18.12 and 18.1 (6×q, CH 3 -TIPS), 12.4 and 12.3 (2×d, CH-TIPS), 11.9 (q, C-18), 7.1 (q, SiCH 2 CH 3 ), 6.8 (t, SiCH 2 CH 3 ).
(b) Hydroxyls deprotection in the silylated vitamin 3 . A solution of HF-pyridine complex (ca 70% HF, 0.1 mL) was added dropwise to a solution of protected 6-methylvitamin 3 (37 mg, 0.086 mmol) in CH 3 CN (0.5 mL), CH 2 Cl 2 (0.25 mL) and Et 3 N (0.25 mL) at 0° C. The reaction mixture was stirred at room temperature for 20 min. Next portion of HF-pyridine complex (0.2 mL) was added during 1 h and the mixture was stirred at room temperature for 2 h. The reaction was cooled to 0° C., quenched by slow addition of saturated aqueous solution of NaHCO 3 , and diluted with AcOEt. Organic phase was washed with saturated aqueous solution of NaHCO 3 , dried (Na 2 SO 4 ) and concentrated. The residue applied on Sep-Pak (2 g) and eluted with hexane/AcOEt (3:7). The product was then purified by HPLC (9.4 mm×25 cm Zorbax-Sil column, 4 mL/min) using hexane/2-propanol (8:2) solvent system and 1α,25-dihydroxy-6-methylvitamin D 3 (4) was eluted at R V 31 mL (16 mg, 86%).
4: UV (in EtOH) λ max 240.0 nm; 1 H NMR (400 MHz, MeOD) δ 5.71 (1H, s, 7-H), 5.15 (1H, br s, 19-H), 4.79 (1H, d, J=1.7 Hz, 19-H), 4.34 (1H, m, 1□-H); 4.13 (1H, m, 3□-H), 2.56 (1H, br d, J=11 Hz, 9□-H), 2.43 (1H, br s), 2.03 (1H, br d), 1.88 (3H, s, 6-CH 3 ), 1.18 (6H, s, 26- and 27-H 3 ), 0.97 (3H, d, J=6.3 Hz, 21-H 3 ), 0.61 (3H, s, 18-H 3 ).
Biological Activity of 1α,25-Dihydroxy-6-Methylvitamin D 3 Analog 4, ME-Cvit
The introduction of a methyl group to the 6-position, as well as a hydroxyl substituent attached to the 25-position (C-25) in the side chain, and having another hydroxyl substituent located at the 1-position (C-1) of the vitamin D 3 compound had little effect on binding of Me-Cvit to the full length recombinant rat vitamin D receptor, as compared to 1α,25-dihydroxyvitamin D 3 . The compound Me-Cvit bound with the same affinity to the nuclear vitamin D receptor as compared to the standard 1,25-(OH) 2 D 3 ( FIG. 1 ). It might be expected from these results that compound Me-Cvit would have equivalent biological activity. Surprisingly, however, compound Me-Cvit is a highly selective analog with unique biological activity.
FIG. 5 shows that Me-Cvit has relatively low ability to increase intestinal calcium transport activity in vivo at low dosages. It clearly has lower potency in vivo (greater than 1,000 times less potent) as compared to that of 1,25-dihydroxyvitamin D 3 (1,25(OH) 2 D 3 ), the natural hormone, in stimulating intestinal calcium transport, especially at the recommended lower doses.
FIG. 4 demonstrates that Me-Cvit also has low bone calcium mobilization activity, as compared to 1,25(OH) 2 D 3 . Me-Cvit demonstrated less bone calcium mobilization activity than 1,25(OH) 2 D 3 (4.3 mg/dL of Me-Cvit versus 7.6 mg/dL of 1,25(OH) 2 D 3 at 7020 pmol dosage). Thus, Me-Cvit clearly is less effective in mobilizing calcium from bone as compared to 1,25(OH) 2 D 3 .
FIGS. 4 and 5 thus illustrate that Me-Cvit may be characterized as being less potent than 1,25(OH) 2 D 3 in promoting intestinal calcium transport activity, and also less potent than 1,25(OH) 2 D 3 in promoting bone calcium mobilization activity.
FIG. 2 illustrates that Me-Cvit is only about 2 logs or 20 times less potent than 1,25(OH) 2 D 3 on HL-60 cell differentiation, i.e. causing the differentiation of HL-60 cells into monocytes. Thus, Me-Cvit may be a candidate for the treatment of a cancer, especially against leukemia, colon cancer, breast cancer, skin cancer and prostate cancer.
FIG. 3 illustrates that in bone cells the compound Me-Cvit is only about 1 log or 10 times less potent than 1,25(OH) 2 D 3 in increasing transcription of the 24-hydroxylase gene. This result, together with the cell differentiation activity of FIG. 2 , suggests that Me-Cvit may be effective in treating the above referred to cancers because it has direct cellular activity in causing cell differentiation, gene transcription, and in suppressing cell growth.
Also, because Me-Cvit binds the receptor with the same affinity as the native hormone but has markedly lower potency in biological calcemic activities downstream from receptor binding, it is possible this compound could act as a dominant negative and be useful as an antidote for vitamin D or analog intoxication. In other words, Me-Cvit may act in vivo as an antagonist against hypercalcemia caused by a vitamin D compound.
Experimental Methods
Vitamin D Receptor Binding
Test Material
Protein Source
Full-length recombinant rat receptor was expressed in E. coli BL21 (DE3) Codon Plus RIL cells and purified to homogeneity using two different column chromatography systems. The first system was a nickel affinity resin that utilizes the C-terminal histidine tag on this protein. The protein that was eluted from this resin was further purified using ion exchange chromatography (S-Sepharose Fast Flow). Aliquots of the purified protein were quick frozen in liquid nitrogen and stored at −80° C. until use. For use in binding assays, the protein was diluted in TEDK 50 (50 mM Tris, 1.5 mM EDTA, pH7.4, 5 mM DTT, 150 mM KCl) with 0.1% Chaps detergent. The receptor protein and ligand concentration were optimized such that no more than 20% of the added radiolabeled ligand was bound to the receptor.
Study Drugs
Unlabeled ligands were dissolved in ethanol and the concentrations determined using UV spectrophotometry (1,25(OH) 2 D 3 : molar extinction coefficient=18,200 and λ max =265 nm; Analogs: molar extinction coefficient=42,000 and λ max =252 nm). Radiolabeled ligand (3H-1,25(OH) 2 D 3 , ˜159 Ci/mmole) was added in ethanol at a final concentration of 1 nM.
Assay Conditions
Radiolabeled and unlabeled ligands were added to 100 mcl of the diluted protein at a final ethanol concentration of ≦10%, mixed and incubated overnight on ice to reach binding equilibrium. The following day, 100 mcl of hydroxylapatite slurry (50%) was added to each tube and mixed at 10-minute intervals for 30 minutes. The hydroxylapaptite was collected by centrifugation and then washed three times with Tris-EDTA buffer (50 mM Tris, 1.5 mM EDTA, pH 7.4) containing 0.5% Titron X-100. After the final wash, the pellets were transferred to scintillation vials containing 4 ml of Biosafe II scintillation cocktail, mixed and placed in a scintillation counter. Total binding was determined from the tubes containing only radiolabeled ligand.
HL-60 Differentiation
Test Material
Study Drugs
The study drugs were dissolved in ethanol and the concentrations determined using UV spectrophotometry. Serial dilutions were prepared so that a range of drug concentrations could be tested without changing the final concentration of ethanol (≦0.2%) present in the cell cultures.
Cells
Human promyelocytic leukemia (HL60) cells were grown in RPMI-1640 medium containing 10% fetal bovine serum. The cells were incubated at 37° C. in the presence of 5% CO 2 .
Assay Conditions
HL60 cells were plated at 1.2×10 5 cells/ml. Eighteen hours after plating, cells in duplicate were treated with drug. Four days later, the cells were harvested and a nitro blue tetrazolium reduction assay was performed (Collins et al., 1979; J. Exp. Med. 149:969-974). The percentage of differentiated cells was determined by counting a total of 200 cells and recording the number that contained intracellular black-blue formazan deposits. Verification of differentiation to monocytic cells was determined by measuring phagocytic activity (data not shown).
In Vitro Transcription Assay
Transcription activity was measured in ROS 17/2.8 (bone) cells that were stably transfected with a 24-hydroxylase (24Ohase) gene promoter upstream of a luciferase reporter gene (Arbour et al., 1998). Cells were given a range of doses. Sixteen hours after dosing the cells were harvested and luciferase activities were measured using a luminometer.
RLU=relative luciferase units.
Intestinal Calcium Transport and Bone Calcium Mobilization
Male, weanling Sprague-Dawley rats were placed on Diet 11 (0.47% Ca) diet+AEK oil for one week followed by Diet 11 (0.02% Ca)+AEK oil for 3 weeks. The rats were then switched to a diet containing 0.47% Ca for one week followed by two weeks on a diet containing 0.02% Ca. Dose administration began during the last week on 0.02% calcium diet. Four consecutive ip doses were given approximately 24 hours apart. Twenty-four hours after the last dose, blood was collected from the severed neck and the concentration of serum calcium determined as a measure of bone calcium mobilization. The first 10 cm of the intestine was also collected for intestinal calcium transport analysis using the everted gut sac method.
Interpretation of Data
Summary of Biological Findings. This compound Me-Cvit binds the VDR with the same affinity as the native hormone, and can be considered to be equally potent as 1,25(OH) 2 D 3 in this activity. Me-Cvit also displays approximately 20 times less cell differentiation activity and about 10 times less in vitro gene transcription activity compared to 1,25(OH) 2 D 3 . While this compound has activity comparable to 1,25(OH) 2 D 3 in vitro, it shows less activity in vivo on bone calcium mobilization compared to the native hormone, and less activity in vivo in promoting intestinal calcium transport compared to the native hormone. Because this compound exhibits relatively significant cell differentiation and transcriptional activity, but relatively low calcemic activity on bone, it might be useful for treating patients with various types of cancers, especially for the treatment of leukemia, colon cancer, breast cancer, skin cancer and prostate cancer. Me-Cvit might not only be useful in the treatment of the above listed cancers, but also in the prevention of the above listed cancers.
Also, because Me-Cvit binds the receptor as well as the native hormone but has markedly lower potency in biological activities downstream from receptor binding, it is possible this compound could act as a dominant negative and be useful as an antidote for vitamin D or analog intoxication. In other words, Me-Cvit may act in vivo as an antagonist against hypercalcemia caused by a vitamin D compound.
VDR binding, HL60 cell differentiation, and transcription activity. Me-Cvit (K i =2×10 −11 M) has about the same activity as the natural hormone 1α,25-dihydroxyvitamin D 3 (K i =3×10 −11 M) in its ability to compete with [ 3 H]-1,25(OH) 2 D 3 for binding to the full-length recombinant rat vitamin D receptor ( FIG. 1 ). Me-Cvit displays about 2 logs or 20 times less activity (EC 50 =8×10 −8 M) in its ability (efficacy or potency) to promote HL-60 cell differentiation as compared to 1α,25-dihydroxyvitamin D 3 (EC 50 =2×10 −9 M) (See FIG. 2 ). Also, compound Me-Cvit (EC 50 =4×10 −9 M) has about 1 log or 10 times less transcriptional activity in bone cells than 1α,25-dihydroxyvitamin D 3 (EC 50 =2×10 −10 M) (See FIG. 3 ). These results suggest that Me-Cvit may have significant activity as an anti-cancer agent and may be very effective because it has direct cellular activity in causing cell differentiation, gene transcription, and in suppressing cell growth.
Calcium mobilization from bone and intestinal calcium absorption in vitamin D-deficient animals. Using vitamin D-deficient rats on a low calcium diet (0.02%), the activities of Me-Cvit and 1,25(OH) 2 D 3 in intestine and bone were tested. As expected, the native hormone (1,25(OH) 2 D 3 ) increased serum calcium levels at all dosages ( FIG. 4 ). The study reported in FIG. 4 shows that Me-Cvit has little activity in mobilizing calcium from bone and is about 400 times less potent than 1,25(OH) 2 D 3 . The administration of 7020 pmol/day of Me-Cvit for 4 consecutive days did not cause mobilization of bone calcium (4.3 mg/dL) but the native hormone 1,25(OH) 2 D 3 had significant activity at 7020 pmol/day where a substantial effect was seen (7.6 mg/dL).
Intestinal calcium transport was evaluated in the same group of animals using the everted gut sac method ( FIG. 5 ). The study reported in FIG. 5 shows Me-Cvit has little intestinal calcium transport activity as compared to 1,25(OH) 2 D 3 . Administration of 7020 pmol/day of Me-Cvit for 4 consecutive days resulted in substantially less activity as compared to 1,25(OH) 2 D 3 at the same 7020 pmol/day dosage (4.8 versus 8.3 respectively).
These results show that the compound Me-Cvit promotes intestinal calcium transport in a dose dependent manner. Thus, it may be concluded that Me-Cvit has lower intestinal calcium transport activity to that of 1,25(OH) 2 D 3 at the recommended lower doses.
These results further illustrate that Me-Cvit is an excellent candidate for numerous human therapies as described herein. Me-Cvit is a candidate for treating a cancer because: (1) it has VDR binding, transcription activity and cellular differentiation activity; (2) it has lower risk of hypercalcemic liability, unlike 1,25(OH) 2 D 3 ; and (3) it is easily synthesized.
Also, because Me-Cvit binds the receptor as well as the native hormone but has markedly lower potency in biological activities downstream from receptor binding, it is possible this compound could act as a dominant negative and be useful as an antidote for vitamin D or analog intoxication. In other words, Me-Cvit may act in vivo as an antagonist against hypercalcemia caused by a vitamin D compound.
For prevention and/or treatment purposes, the compounds of this invention defined by formula I, particularly Me-Cvit, may be formulated for pharmaceutical applications as a solution in innocuous solvents, or as an emulsion, suspension or dispersion in suitable solvents or carriers, or as pills, tablets or capsules, together with solid carriers, according to conventional methods known in the art. Any such formulations may also contain other pharmaceutically-acceptable and non-toxic excipients such as stabilizers, anti-oxidants, binders, coloring agents or emulsifying or taste-modifying agents.
The compounds of formula I and particularly Me-Cvit, may be administered orally, topically, parenterally, rectally, nasally, sublingually or transdermally. The compound is advantageously administered by injection or by intravenous infusion or suitable sterile solutions, or in the form of liquid or solid doses via the alimentary canal, or in the form of creams, ointments, patches, or similar vehicles suitable for transdermal applications. A dose of from 0.01 μg to 1000 μg per day of the compounds I, particularly Me-Cvit, preferably from about 0.1 μg to about 500 μg per day, is appropriate for prevention and/or treatment purposes, such dose being adjusted according to the disease to be treated, its severity and the response of the subject as is well understood in the art. Since the compound exhibits specificity of action, each may be suitably administered alone, or together with graded doses of another active vitamin D compound—e.g. 1α-hydroxyvitamin D 2 or D 3 , or 1α,25-dihydroxyvitamin D 3 —in situations where different degrees of bone mineral mobilization and calcium transport stimulation is found to be advantageous.
Compositions for use in the above-mentioned treatments comprise an effective amount of the compounds I, particularly Me-Cvit, as defined by the above formula I and Ia as the active ingredient, and a suitable carrier. An effective amount of such compound for use in accordance with this invention is from about 0.01 μg to about 1000 μg per gm of composition, preferably from about 0.1 μg to about 500 μg per gram of composition, and may be administered topically, transdermally, orally, rectally, nasally, sublingually, or parenterally in dosages of from about 0.01 μg/day to about 1000 μg/day, and preferably from about 0.1 μg/day to about 500 μg/day.
The compounds I, particularly Me-Cvit, may be formulated as creams, lotions, ointments, topical patches, pills, capsules or tablets, suppositories, aerosols, or in liquid form as solutions, emulsions, dispersions, or suspensions in pharmaceutically innocuous and acceptable solvent or oils, and such preparations may contain in addition other pharmaceutically innocuous or beneficial components, such as stabilizers, antioxidants, emulsifiers, coloring agents, binders or taste-modifying agents.
The compounds I, particularly Me-Cvit, may be advantageously administered in amounts sufficient to effect the differentiation of promyelocytes to normal macrophages. Dosages as described above are suitable, it being understood that the amounts given are to be adjusted in accordance with the severity of the disease, and the condition and response of the subject as is well understood in the art.
The formulations of the present invention comprise an active ingredient in association with a pharmaceutically acceptable carrier therefore and optionally other therapeutic ingredients. The carrier must be “acceptable” in the sense of being compatible with the other ingredients of the formulations and not deleterious to the recipient thereof.
Formulations of the present invention suitable for oral administration may be in the form of discrete units as capsules, sachets, tablets or lozenges, each containing a predetermined amount of the active ingredient; in the form of a powder or granules; in the form of a solution or a suspension in an aqueous liquid or non-aqueous liquid; or in the form of an oil-in-water emulsion or a water-in-oil emulsion.
Formulations for rectal administration may be in the form of a suppository incorporating the active ingredient and carrier such as cocoa butter, or in the form of an enema.
Formulations suitable for parenteral administration conveniently comprise a sterile oily or aqueous preparation of the active ingredient which is preferably isotonic with the blood of the recipient.
Formulations suitable for topical administration include liquid or semi-liquid preparations such as liniments, lotions, applicants, oil-in-water or water-in-oil emulsions such as creams, ointments or pastes; or solutions or suspensions such as drops; or as sprays.
For nasal administration, inhalation of powder, self-propelling or spray formulations, dispensed with a spray can, a nebulizer or an atomizer can be used. The formulations, when dispensed, preferably have a particle size in the range of 10 to 100μ.
The formulations may conveniently be presented in dosage unit form and may be prepared by any of the methods well known in the art of pharmacy. By the term “dosage unit” is meant a unitary, i.e. a single dose which is capable of being administered to a patient as a physically and chemically stable unit dose comprising either the active ingredient as such or a mixture of it with solid or liquid pharmaceutical diluents or carriers. | This invention discloses 6-methylvitamin D 3 analogs, and specifically 1α,25-dihydroxy-6-methylvitamin D 3 , and pharmaceutical uses therefor. This compound exhibits vitamin D receptor binding activity and transcription activity as well as activity in arresting the proliferation of undifferentiated cells and inducing their differentiation to the monocyte thus evidencing use as an anti-cancer agent, especially for the treatment or prevention of leukemia, colon cancer, breast cancer, skin cancer or prostate cancer. This compound also exhibits low in vivo calcemic activity, but because it binds the receptor with the same affinity as the native hormone calcitriol, it may act as an antagonist to inhibit development of hypercalcemia. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 11/961,465, which was filed on 20 Dec. 2007 and is incorporated herein by reference.
BACKGROUND
[0002] This invention relates to influencing airbag inflation using a duct.
[0003] Known airbag systems protect vehicle occupants by absorbing forces generated during collisions, for example. Many airbag systems are used in conjunction with other vehicle safety systems, such as seatbelts. Safety systems protect occupants located in various positions within the vehicle.
[0004] In particular, airbag designs within some safety systems protect both “in-position” occupants and “out-of-position” occupants. Typically, during a collision, an “in-position” occupant directly strikes a contact face portion of the airbag, whereas an “out-of-position” occupant does not directly strike the contact face. Balancing protection of “in-position” occupants with protect of “out-of-position” occupants is often challenging. Through the contact face, the airbag absorbs forces from the occupant that are generated during the collision.
[0005] Generally, it is desirable to provide a softer airbag during the initial stages of airbag deployment. It is also often desirable to provide a harder airbag when the airbag is fully deployed and when the occupant is an “in-position” occupant. As known, occupants may move between the “out-of-position” occupant position and the “in-position” occupant position. Many airbags include vents for changing the softness or the hardness of the airbag as the airbag deploys, but the occupant position does not affect airflow through the vents.
SUMMARY
[0006] An exemplary airbag assembly includes an airbag and a duct having an duct opening for venting gas. The duct has a first position and a second position. The duct is configured to direct less gas out of the airbag when in the second position than when in the first position. A tether kinks about the duct to move the duct from the first position to the second position. The inflating causes the tether to kink about the duct.
[0007] Another exemplary airbag assembly includes an airbag and a duct. A portion of the duct is moveable from a first position to a second position. A clamping tether clamps the duct to move the duct from the first position and the second position. The duct directs more gas out of the airbag in the first position than in the second position.
[0008] An exemplary airbag inflation method includes directing fluid outside an interior of an airbag using a duct and inflating the airbag to clamp a tether about the duct to lessen said directing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description:
[0010] FIG. 1A shows a side view of example “out-of-position” occupants within a vehicle.
[0011] FIG. 1B shows a side view of an example “in-position” occupant within a vehicle.
[0012] FIG. 2A shows a partially schematic top view of an example airbag assembly having an airbag in a partially expanded position.
[0013] FIG. 2B shows another partially schematic top view of the FIG. 2A airbag assembly having the airbag in a fully expanded position.
[0014] FIG. 3 shows a perspective view of a duct portion of the FIG. 2A airbag assembly.
[0015] FIG. 4A shows a partially schematic top view of another example airbag assembly having an airbag in a partially expanded position.
[0016] FIG. 4B shows a partially schematic top view of the FIG. 4A airbag assembly having the airbag in a fully expanded position.
[0017] FIG. 5A shows a partially schematic top view of yet another example airbag assembly having an airbag in a partially expanded position.
[0018] FIG. 5B shows a partially schematic top view of the FIG. 5A airbag assembly having the airbag in a fully expanded position.
[0019] FIG. 6 shows a partially schematic top view of yet another example airbag assembly having an airbag in a fully expanded position.
[0020] FIG. 7 shows a partially schematic top view of yet another example airbag assembly having an airbag in a fully expanded position.
DETAILED DESCRIPTION
[0021] FIG. 1A illustrates “out-of-position” occupants 20 within a vehicle 28 . As known, “out-of-position” occupants 20 can tend to crowd the airbag deployment area 32 more than an “in-position” occupant 24 shown in FIG. 1B .
[0022] In this example, the “out-of-position” occupants 20 are undesirably located near an airbag deployment area 32 . By contrast, the “in-position” occupant 24 desirably provides clearance for an airbag to expand from the airbag deployment area 32 . As generally known, providing a harder airbag is often desired for the “in-position” occupant 24 , but not desired for the “out-of-position” occupants 20 .
[0023] Referring now to FIGS. 2A and 2B , an example airbag assembly 50 includes an airbag 54 having at least one duct 58 . A duct opening 62 or duct vent at an end of the duct 58 permits gas 78 movement from the duct 58 . An airbag inflator 66 , represented schematically here, generates gas 78 , which is moved into another end of the duct 58 and into the interior portion of the airbag 54 . Accordingly, the airbag inflator 66 moves gas 78 that both inflates the airbag 54 , and gas 78 that escapes outside of the airbag 54 through the duct opening 62 . The duct 58 and the airbag 54 are secured adjacent the airbag inflator 66 .
[0024] The duct opening 62 extends outside the airbag 54 through the duct opening 62 when the airbag 54 is partially deployed, but not when the airbag 54 is fully deployed. As the airbag 54 inflates, the duct opening 62 moves inside the airbag 54 . Distance d 1 in FIG. 2A and greater distance D 1 in FIG. 2B represent example distances between an airbag opening 82 and the attachment points of the duct 58 and the airbag 54 near the airbag inflator 66 . The duct 58 is too short to extend the duct opening 62 outside the airbag 54 through the airbag opening 82 after the airbag 54 is inflated some amount.
[0025] Moving the duct 58 within the interior of the airbag 54 changes the location of the duct opening 62 . In this example, filling the airbag 54 with gas 78 from the duct opening 62 hardens the airbag 54 . As known, hardening the airbag 54 is generally desired during the later stages of deployment, not when the airbag 54 initially deploys. Accordingly, the example assembly 50 pulls the duct opening 62 within the airbag 54 as the airbag 54 approaches the fully deployed position of FIG. 2B , which ensures that the gas 78 moving from the duct opening 62 does not contribute to expanding the airbag 54 during initial deployment of the airbag 54 or when the “out-of-position” occupant of FIG. 1A limits movement of a contact face 74 portion of the airbag 54 .
[0026] The airbag 54 has softer characteristics during the earlier stages of deployment, say the first 20 milliseconds of deployment, because some of the gas 78 vents to the outside environment through the duct opening 62 . As known, softer characteristics of the airbag 54 are desired for “out-of-position” occupants 20 and during initial stages of airbag deployment. Associating the position of the contact face 74 with the characteristics of the airbag 54 facilitates accommodating the “out-of-position” occupant 20 and the “in-position” occupant 24 .
[0027] Referring now to FIG. 3 , the duct 58 includes a duct mouth 68 for receiving gas 78 from the airbag inflator 66 ( FIG. 2A ). The shape of the duct 58 tends to direct air from the mouth 68 toward the duct opening 62 . The duct 58 is flexible and foldable with the airbag 54 in the airbag deployment area 32 ( FIG. 1A ) when the airbag 54 is not inflated. A person skilled in this art would know how to direct gas 78 into both the duct 58 and the interior portion of the airbag 54 and how to design a suitable duct 58 for incorporation into the airbag assembly 50 .
[0028] In the example of FIGS. 4A and 4B , the duct 58 attaches directly to an interior surface of the airbag 54 , which closes the duct opening 62 ( FIG. 3 ) to prevent venting gas 78 from the duct 58 outside the airbag 54 . Instead, gas 78 fills the duct 58 forcing the sides of the airbag 54 outward in directions Y. Filling the duct 58 forces the sides of the airbag 54 outward during the early stages of airbag 54 deployment. Without the duct 58 , the sides of the airbag 54 move outward as the interior of the airbag 54 fills, rather than as the interior of the duct 58 fills. In this example, the airbag 54 may include discrete vents 64 for venting gas 78 directly from the interior of the airbag 54 . As known, discrete vents 64 help soften the deploying airbag 54 .
[0029] Referring now to FIGS. 5A and 5B in another example, the interior of the airbag 54 may include at least one tether 70 for moving the duct 58 relative the airbag 54 . As shown, the tether 70 secures the duct 58 to an interior surface 72 of the airbag 54 . In this example, one end of the tether 70 attaches to the interior surface 72 of the airbag near a contact face 74 of the airbag 54 opposing the airbag inflator 66 , and another end of the tether 70 attaches directly to the duct 58 . The ends of the tether 70 are respectively sewn to the interior surface 72 of the airbag 54 and the duct 58 , for example. Accordingly, moving the interior surface 72 of the airbag 54 moves the tether 70 , which moves the duct 58 .
[0030] The airbag opening 82 within the airbag 54 facilitates moving the duct 58 relative other portion of the airbag 54 . In this example, moving the contact face 74 moves the tether 70 , which pulls the duct 58 inside the airbag 54 . Ordinarily, the contact face 74 is the portion of the airbag 54 for contacting an occupant 20 , 24 ( FIGS. 1A-1B ). Thus, in this example, the tether 70 does not pull the duct 58 fully inside the airbag 54 until the contact face 74 extends sufficiently away from the airbag deployment area 32 . Distance d 2 in FIG. 5A and greater distance D 2 in FIG. 5B represent example distances between the airbag opening 82 and the attachment location of the tether adjacent the contact face 74 .
[0031] The contact face 74 of the airbag 54 moves further as the airbag 54 deploys. As known, during deployment of the airbag 54 , the “out-of-position” occupant 20 of FIG. 1A would strike the contact face 74 of the airbag 54 sooner than the “in-position” occupant 24 of FIG. 1B . Moving the contact face 74 increases the distance between the contact face 74 and the attachment point of the tether 70 to the duct 58 . Limiting movement of the contact face 74 , such as with the “out-of-position” occupant 20 of FIG. 1A , would prevent or otherwise limit movement of the tether 70 and the duct 58 , and would cause the duct 58 to continue to vent outside of the airbag 54 until the occupant 20 moves to permit expansion of the contact face 74 .
[0032] Moving the duct 58 within the airbag 54 does permit some gas 78 to escape from the airbag 54 through the airbag opening 82 . However, the duct 58 provides a more direct path between the gas 78 from the airbag inflator 66 and the outside of the airbag 54 . Thus the amount of the gas 78 moving from the airbag inflator 66 and through the duct opening 62 , is greater than the amount of gas 78 moving from the airbag inflator 66 to the interior of the airbag 54 and through the airbag opening 82 when the duct 58 is fully within the airbag 54 .
[0033] In the FIG. 6 example, the airbag assembly 50 include at least one clamping tether 86 that closes the duct 58 to restrict flow of gas 78 through the duct opening 62 during the latter stages of airbag 54 deployment. In such an example, the clamping tether 86 kinks the duct 58 as the contact face 74 moves away from the airbag deployment area 32 . As previously described, moving the airbag contact face 74 away from the airbag deployment area 32 moves the tether 86 , which, in this example, causes the tether 86 to kink the duct 58 . In this example, the duct 58 does not move within the airbag opening 82 . Stitches 87 may secure the duct 58 relative the airbag 54 .
[0034] Kinking the duct 58 with the tether 86 restricts flow through the duct 58 . As a result, gas 78 that would formerly move outside the airbag 54 through the duct opening 62 stays within the airbag 54 . As previously described, providing more air or more gas 78 to the interior of the airbag 54 hardens the airbag 54 . As flow through the duct 58 is blocked, the airbag inflator 66 directs gas 78 formerly directly through the duct 58 directly into the interior of the airbag 54 .
[0035] In the example of FIG. 7 , the tether 86 pulls a flap 94 on the duct 58 , which permits gas 78 to escape through an aperture 98 within the duct 58 into the interior of the airbag 54 . Accordingly, as the contact face 74 expands, the tether 86 opens the aperture to direct more gas 78 into the interior of the airbag 54 . A hook and loop fastener may secure the flap 94 over the aperture 98 until the tether 86 opens the flap 94 .
[0036] Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. | An exemplary airbag assembly includes an airbag and a duct having an duct opening for venting gas. The duct has a first position and a second position. The duct is configured to direct less gas out of the airbag when in the second position than when in the first position. A tether kinks about the duct to move the duct from the first position to the second position. The inflating causes the tether to kink about the duct. | 1 |
TECHNICAL FIELD
This invention is in the field of mold making, particularly the manufacture of molds for use in injection molding from relatively soft metals which nevertheless can be used for large numbers of reproductions of the molded article.
BACKGROUND OF THE INVENTION
Conventionally, relatively soft metals such as zinc and zinc alloys, particularly alloys with aluminum and/or magnesium, are used for plastic injection molds only when small numbers of prototypes are desired and/or when quality is not critical for the initial study of a prototype. Where larger numbers of the molded piece or article are needed, say, more than one hundred, and/or where quality is necessary even for a few prototypes, the molds are typically made from steel at much higher cost because of the skilled labor, time and material required.
The art is in need of a method of quickly making relatively inexpensive molds capable of making large runs of thermoplastic pieces, i.e. more than 100 and frequently many more than 100.
SUMMARY OF THE INVENTION
Our invention is a method of making a mold of at least 50% zinc in at least two parts as a negative replica of a pattern. Unlike processes of the past, our procedure assures that the zinc mold will have a useful life far beyond the usual few reproductions normally expected from molds of relatively soft metal such as zinc. Our process will make a mold capable of making at least one hundred units by thermoplastic injection molding without significant degradation, and will make it in a short time of great advantage in the marketplace.
Our invention is an improvement in the process known as plaster mold casting; we use plaster mold casting to make a zinc (or zinc alloy) mold, and we advantageously combine our process with one of the new computer-controlled processes for pattern making known as rapid prototyping. Our improvement is primarily in the particular manner in which we use and set the metal. As in conventional plaster mold casting, we employ a pattern which is a three-dimensional replica of the final desired product--in this case a thermoplastic product--built to anticipate shrinkage and to incorporate a draft to facilitate separation and removal in the various steps including the final thermoplastic molding step. As is also well known in the molding art, the pattern will be slightly larger than the desired final product, and surfaces normally parallel to the direction of separation or removal (the draw) will manifest a slight taper, or draft. The pattern is preferably made by one of the recently developed processes known as "rapid prototyping", generally based on computerized three-dimensional models which are used to control systems for building the prototypes or patterns. Among such systems is "laminated object manufacturing", by which sheets of paper or paper-like material, usually fed from a roll, are fed to a cutting zone where they are cut by a computer-controlled laser beam and adhered to each other in layers, thus building the pattern from thin layers of material. Another system is known as selective laser sintering. In this method, powdered material which can be sintered is fused one layer at a time by a laser beam which acts on instructions from a computer. In stereolithography, a similar layer-by-layer construction is achieved from a pool of liquid polymerizable or curable material. Fused deposition modeling utilizes a thin filament of curable material, also following a path dictated by a computer, to build the model one thin layer at a time. Solid ground curing uses incremental photomasks to expose a liquid photocurable pattern to ultraviolet light or other photoactivating energy. Our method is especially suitable for use with these and other rapid prototyping methods (defined herein as computer-aided incremental pattern building) because the combination of rapid prototyping and our mold construction method utilizing improved zinc mold treatment yields a very fast, reliable, and highly economic method of making prototypes of new products which would otherwise require months. Specifically, using rapid prototyping methods for pattern making in combination with our zinc mold manufacturing method can drastically reduce the time from design to injection molded product. In the past, the time from pattern to injection molding was typically eight to ten weeks; with our process it is commonly two weeks. In combination with rapid prototyping methods, our method permits the designer to have his actual product in quantities and times, and at a low expense, that permits him to experiment and adjust with much more flexibility and still meet tight scheduling demands. Our process is fast, accurate, and permits enough injection molded prototypes to be made so that the designer can even test market if he or she desires.
The pattern is placed on a work base and filler is placed around it to define a mold part line and a first exposed portion of the pattern; a frame is constructed around the pattern in sealed relationship to the work base, locator posts may be provided to assure exact placement of the mold parts with respect to each other, as is known in the art, and a negative is made of the first exposed portion by covering it with a liquid which cures to a rubbery solid as is known in the art. After curing, a plaster such as a dental plaster is poured over the rubber to fill the complete internal volume of the frame. After the plaster sets, the assembly including the rubbery solid with the negative is inverted, the filler removed, and a second rubbery solid is constructed by pouring the liquid curable material on top of the second exposed portion of the pattern, preferably after first coating the first rubbery solid with a mold release or equivalent material in order to prevent adherence of the second rubbery solid to the first. Plaster may be used to fill the volume next to the rubbery solids. The rubbery solid shapes are separated, the pattern removed, and the rubbery solids are placed within framed areas on a work base and surrounded with sand so the volume above them can be filled with a slurry of sand, water, and gypsum cement, taking the shape of the rubbery solid, and then permitted to solidify to form replicas of the two defined halves of the pattern. The solidified cement halves are then heated in an oven to remove virtually all free moisture, usually for about 72 hours at 300° F., making them quite hard. Molten metal, preferably zinc or a zinc alloy, is then poured into these cement halves, and permitted to solidify slowly, with the application of heat from a flame directly into the center of any sinkhole which may form; more metal is added to the sinkhole to maintain its approximate original level. When the zinc becomes hard, the two blocks of zinc mold are clamped to a solid steel surface and the clamps are adjusted throughout the cooling process to maintain the block in contact with the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a shows the initial creation of two solid rubber negatives of a pattern, and FIGS. 1b and 1c show the formation of plaster reproductions of their surfaces.
FIGS. 2a and 2b depict the pouring of zinc metal or an alloy onto the surfaces of the plaster reproductions, and treatment to assure proper cooling.
FIGS. 3a and 3b show a preferred procedure for clamping of the metal mold during cooling.
DETAILED DESCRIPTION OF THE INVENTION
The present invention involves the steps of (a) making a pattern--that is, an exact shape or replica of the desired article except for an increase in the dimensions of about 1.5% more or less, depending on the plastic molding material to be used, to allow for shrinkage; preferably the pattern is made by rapid prototyping as defined above (b) determining the position of a mold part line for two mold parts, with respect to the pattern; the mold parts may be referred to as the stationary part and the moving part, as they are to be utilized in the injection molding machine (c) determining the direction of relative movement of the two mold parts relative to each other to open and close the mold, and the direction the moving part will move, the draw, is perpendicular to the parting line (d) adjusting the pattern to provide a draft on all surfaces of the pattern which are approximately parallel to the proposed relative movement but tapered slightly with a draft as known in the art to prevent binding during movement of the mold and/or during mold release (e) placing the pattern on a work base (f) placing a filler such as clay at the mold line of the pattern to seal off a mold part surface oriented toward the work base and leave the other mold part surface exposed, and to seal off portions of the pattern which, if filled with metal, would interlock and/or otherwise not permit the separation of the two mold parts (g) providing a steel or other strong frame around the pattern on the work base, sealed to the work base, and extending to a point higher than the pattern, (h) placing locator posts or other tangible reference points near the frame, preferably anchored to the work base, (i) pouring a liquid rubber into the frame to completely cover the pattern (extend over it at least about an inch and be retained by the frame (j) permitting the liquid rubber to solidify (k) after the rubber is solidified, fill the rest of the frame with a plaster which may be referred to herein as the preferred dental plaster by pouring it over the rubber (l) after the dental plaster solidifies, remove the entire assembly (pattern, rubber and dental plaster) from the frame and turn it over so the pattern is now on top (m) remove the clay from the pattern to expose the entire surface of the pattern which had been oriented toward the work base (n) place a frame around the assembly (sealed against the rubber around its periphery); the frame extends some distance above the pattern and is preferably reinforced according to the peculiarities of the pattern, to guard against fracturing of the Hydroperm to be employed in step (w), (o) apply mold release agent to the exposed rubber surface (p) pour more liquid rubber into the space to a depth about the same as the thickness of the already solidified rubber on the other side of the pattern; the mold release agent prevents permanent adherence of the two portions of rubber (q) permit this second portion of rubber to solidify (r) pour dental plaster into the remaining space over the newly solidified rubber (s) permit the dental plaster to solidify (t) after curing of rubber and solidification of plaster, the frame is removed, the two halves are separated, and the pattern is removed (u) each half is now placed within its own heavy steel frame which allows room for an inch or so of sand around it (v) fill the area between the plaster/rubber assembly and the frame with sand approximately to the level of the rubber (w) fill the remaining area with "Hydroperm" or other gypsum cement to the top of the frame, which may be reinforced to minimize fracturing during casting; the Hydroperm is first mixed to a workable viscosity with sand and water (with the sand having an average particle size less than about 0.02 inch) to act as a heat sink (x) perform steps v and w on the other side (y) permit the "Hydroperm" to solidify and thus reflect the pattern (z) lift up the Hydroperm in its frame; the sand collapses and the rubber and dental plaster units are separated from the Hydroperm (aa) dry the Hydroperm in an oven for three days (bb) with a frame around the Hydroperm, pour the mold metal (zinc or zinc alloy) onto the Hydroperm to a depth of at least one-half inch (cc) permit the zinc to cool/solidify only gradually over a period of about one-half hour to about two hours by directing a gas flame toward the center of the metal box; add more zinc or other metal as sinkholes appear in the center of the block (dd) when the zinc or other metal is solidified, clamp the resulting solid metal mass at the corners to assure firm contact with a substantial base such as a two inch thick block of steel. This must be done before it cools below 510° F. The metal is then permitted to cool at ambient temperatures, while adjusting the clamps frequently (for example, every three minutes) to assure firm contact with the steel surface until the temperature of the metal is below about 450° F. and preferably until it is about 400° F. The metal will be found to have assumed the shape required for an excellent injection mold, retaining the slight oversize necessary to allow for shrinkage of the plastic.
It should be understood that there are many details of manipulation and technique which may be varied in the user's discretion. For example, when the rubbery solid negatives are made, the next step is best approached by creating a volume of plaster on top of the rubbery solid, as stated in step (k) of the Detailed Description of the Invention, above. The exact manner and composition for accomplishing this is a matter of preference within the skill of the art.
Referring now to the drawings, FIG. 1a may be understood by referring to step (s) and the immediately preceding steps in the above detailed description. Frame 6 retains the dental plaster 4 and 5 on top and bottom and the solidified rubber portions 2 and 3 which have profiles defined by pattern 1. Locator posts 24 may be optionally placed as shown. In FIG. 1b, the lower rubber portion 3 from FIG. 1a has been placed as suggested in step (u) of the detailed description into its own frame 7 and the upper rubber portion 2 from FIG. 1a has been placed in its own frame 10 in FIG. 1c, also as suggested in step (u) above. In FIG. 1b, the dental plaster 4 and rubber portion 3 are separated from frame 7 by sand 9; in FIG. 1c, sand 9 separates dental plaster 5 and rubber section 2 from frame 10. Hydroperm fills spaces 8 and 11 in FIGS. 1b and 1c as recited in step (w).
Steps (bb) and (cc) of the detailed description above is shown in FIGS. 2a and 2b. Frames 12 and 15 contain the Hydroperm sections 8 and 11 while zinc metal 13 is poured from ladle 14 to form the metal mold section 16, The metal mold section to be made in FIG. 2a will have a contour defined by Hydroperm section 8, and the metal mold section 16 will have a contour defined by Hydroperm section 11. As suggested in step (cc), the cooling procedure is retarded in FIG. 2b by impinging on the metal mold section 16 a flame 20 from burner 19 and pouring additional metal 22 from ladle 14 to fill sinkholes 23 which may develop in the metal mold section 16, typically in the center.
For FIGS. 3a and 3b, reference is made to step (dd) above. Metal mold section 16 is clamped to base 17 by clamps 18 which are adjusted as recited in step (dd) and the sentences following step (dd).
The above description is our preferred process in some detail. It should be understood that the dental plaster could be replaced by any of several types of plaster known as plaster of paris. The liquid rubber referred to in step (i) forms a rubber or rubbery solid; it is generally made from a 2-component system of catalyst and silicone polymerizate in a weight ratio of about 1:10. A preferred system is a condensation cured silicone designated by its manufacturer, Loctite Corporation of Newington, Conn., as V-1065. Hydroperm, our preferred material for step (w) above, is a trademark of the United States Gypsum Company for its gypsum cement sold for mold making; this material may be mixed to a workable slurry for our purposes with sand and water, generally using Hydroperm in amounts from about 25 to 50 percent by weight with sand at about 30-50% and water at about 20-35%; a preferred mixture is Hydroperm:sand:water in ratios 31:42:27 by weight, less exactly about (27-35):(38-46):(23-31). The zinc or zinc alloy can be an alloy of 50% to 100% zinc with aluminum, commercially available suitable alloys include ZA-2, ZA-8, ZA-12, and ZA-27, the numbers in each representing the approximate percentage of aluminum in the alloy, the balance of which is zinc.
Our invention provides the art with a unique way to expeditiously make injection molds which exhibit a minimum of warpage and which will last far longer than many common non-ferrous molds. When combined with use of patterns made from rapid prototyping, the time from conception of design to working prototype or test market model is drastically reduced. | A method is disclosed for making molds for use in injection molding wherein a cement replica is made of a pattern by curing the cement in a silicon rubber negative of the pattern, then pouring molten zinc or zinc alloy into a frame containing the cement replica. The cooling of the mold metal is controlled by the direct application of flame and frequent adjustments of clamps which firmly contact the mold to a solid surface. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of prior copending application Ser. No. 356,124, filed May 1, 1973 now U.S. Pat. No. 3,868,834.
FIELD OF THE INVENTION
This invention relates to a portable knitting device having a rotary sinker and improved needle bed.
BACKGROUND OF THE INVENTION
In my above co-pending application I described and claimed a knitting device comprising a needle bed, a plurality of equidistantly spaced substantially parallel needles in the needle bed and a sinker consisting of a shaft having a pair of opposed ends, a hook formed on one of said ends of said shaft, a bushing on said shaft in proximate relation to said hook, said bushing having a tapered leading thread, said thread having a larger root diameter adjacent the hook and a small root diameter as it approaches the other end of the shaft, whereby upon rotation of said sinker and movement of the sinker along the needle bed, working yarn or material can be sequentially drawn from between the needles.
Although the arrangement of the knitting device disclosed in my issued U.S. Pat. No. 3,868,834 is perfectly satisfactory, I have now perfected an improved needle bed which facilitates the operation of the device. The prior arrangement of my issued U.S. Pat. No. 3,868,834, as with all other prior arrangements of which I am aware, contemplates the use of metallic needles whereas with the present invention I propose using needles of plastics material. By using needles made of a flexible plastics material, adjacent pairs of needles may move apart as yarn is drawn from the gap between them and the barbs of the needles may be depressed more easily during the knitting operation. Comparable metallic needles of conventional design have minimal lateral flexibility and would require up to ten times the force to depress their barbs, thus making them unsuitable for light, hand-operated knitting devices such as specified in my present application.
Another improvement in my present needle bed is the inclusion of intermediate depressor plates at intervals which facilitate the depression of the barbs of the needles by providing fixing points for a locking bar intermediate the ends of the bed. This limits the distortion of the bed and permits a light construction.
In prior U.S. Pat. No. 2,239,212 and other simple machines descended from the metal Lee stocking frame, the needle beds' supports and locking bar are of heavy construction owing to the considerable force required to depress all the barbs of the needles at the same time and to avoid distortion of the beds. In my invention, the depressor plates and the plastic needles limit distortion to the degree that the shaft of the sinker may be used as a locking bar.
SUMMARY OF THE INVENTION
According to the present invention a knitting device comprises a needle bed, a plurality of equidistantly spaced substantially parallel barbed needles in said needle bed, at least two depressor plates one depressor plate disposed at each end of said needle bed, a retaining notch in each depressor plate and a sinker whereby on rotation and movement of the sinker along said needle bed said sinker sequentially draws working yarn or material from between the needles and on completion of a row of stitches along said needle bed the barbs of said needles may be releasably closed by locating a locking bar between said retaining notches so that said row of stitches may be passed to the bottom of said needles to form a row of stitches in a knitted article.
The invention also includes a knitting device comprising a sinker and a needle bed formed of a plurality of plastics, or other resilient material, barbed needles releasably secured together between two depressor plates by at least one retaining bar, the sinker in use being adapted on rotation to sequentially draw working yarn from between the needles and on completion of the loops of a row being moved to a retaining position between the depressor plates in which the barbs of the needles are held closed allowing the yarn to be moved over the needles.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a side view of one suitable sinker,
FIG. 2 is an end view of the sinker of FIG. 1,
FIG. 3 is a side view of a needle,
FIG. 4 is a sectional view on 4--4 of FIG. 3,
FIG. 5 is a broken away perspective view of the device in use,
FIG. 6 is an end view in the direction of arrow A of FIG. 5,
FIGS. 7a and 7b are views from opposite sides of an alternative sinker having a varying leading thread,
FIG. 8 illustrates an alternative form of depressor plate in side elevation,
FIG. 9 is a broken-away plan view of the needle bed showing a sinker picking up yarn from between plastic needles, and
FIG. 10 is a plan view of a needle bed in which the barbs of the needles have been closed by the shaft of the sinker.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings a knitting device comprises a sinker 1 and a plurality of needles 2 connected together by two retaining bars 3 to form a needle bed. The sinker 1 is formed with a hook 4, a neck 5 and a shaft 6. The hook 4 is arcuately curved about the longitudinal axis of the sinker as clearly seen from FIG. 2 and adjoins the neck 5 which is of larger diameter than the shaft 6: preferably the hook 4 and neck 5 are formed as an integral plastics moulding which fits over the end of the shaft 6 which is preferably made of a metallic material. The neck 5 has a tapered leading thread from a larger root diameter adjacent the hook 4 to a smaller diameter adjacent the shaft 6 in use to propel the sinker forward. The shaft 6 of the sinker 1 serves to transmit rotary motion to the hook and to retain the loops formed. It is of reduced diameter in order to minimise friction and is lightly splined as at 7 to make it easier to twirl between the fingers; the shaft 6 extends the length of the needle bed.
The needles 2 are each made of moulded plastics material, preferably nylon, and have a base 8 and a barb 9. The base 8 of a needle 2 has two holes 10 through which retaining bars 3 pass and a recess 11. Referring particularly to FIG. 3 it will be seen that the base 8 is formed with a slight bend 12, below the barb 9, within which the recess 11 is formed.
At each end of the needle bar, a depressor plate 13 is located. If a large needle bed is employed, then one or more additional intermediate depressor plates 26 are situated at thirty to fifty needle intervals. Plate 13 has a body portion 14 formed with two holes 15 corresponding to holes 10 and an extension portion 16. The extension portion 16 lies adjacent the barbs 9 of the needles 2 and has a notch 17 and a rebate 18 formed in its underside as viewed in FIGS. 5 and 6.
As seen from FIGS. 5 and 6 the end depressor plate 13 and the intermediate depressor plate 26 are similar. Plate 26 differs slightly from plate 13 in that rebate 18 is closed in the end depressor plate to retain a depressor bar 25.
FIGS. 7a and 7b illustrate an alternative sinker 20 in which the angle of the leading threads 21 relative to the axis of shaft 22 is not constant, as in an ordinary screw-thread, but varies around the circumference in such a way that, for every rotation of the shaft, there is a pause in the movement of the head of the sinker in the axial direction along the bed during that part of rotation when the hooked portion is engaged in the needle bed 24, and a compensatingly large movement of the head of the sinker in the axial direction along the bed when the hook has rotated free from engagement with the needle bed. That is, the threads 21 may be at right angles to the shaft 22 on the hook side and at a steep angle on the other. The variation in the angle of the thread about the circumference of the sinker allows the hook 23 to move past the points of the needles and through the gaps between the needles at approximately a right angle to the plane of the bed 24. This refinement tends to reduce rubbing and the possibility of snubbing the yarn between the hook 23 and the end of a needle as the yarn feeds into a new loop.
FIG. 8 shows an alternative form of depressor plate 13 for use particularly when the shaft of the sinker is being used as a depressor bar.
In operation the needles 2 are secured together by passing retaining bars 3 through holes 10 of the needles and holes 15 of the depressor plates 13 and tightening a nut fixture on one end of each bar 3. The first row of stitches is done without the aid of a sinker in the following manner: a slipknot is made over the first needle in the row and the working yarn is wound over the thickened portions of each needle (i.e. the hooks) in the form of a loop. The loops are then pushed towards the bases 8 of the needles to form a loose ruffle. The free end of the yarn (which now extends from the end of the needle bed remote from the end having the slipknot) is then slid under the plates 13 and over the barbs 9 of the needles in such a way as to bring it around under the barbs and into the needle hooks.
Following this operation the slack in the yarn at the point where it joins the previous row is taken up. The sinker is then taken in the operator's hand and the hook 4 placed in the space between the first and second needles of the row so as to engage the newly loaded yarn. The sinker, after it has picked up the first one or two stitches, is then grasped lightly at its far end and rotated between the fingers. Referring particularly to FIG. 1 the completed loops are formed around the leader threads which allow the loops to slacken somewhat after they are formed due to the taper so that friction is reduced.
Referring now particularly to a device with depressor plates as shown in FIGS. 8, 9 and 10, after all the loops have been formed by rotating the sinker as illustrated in FIG. 9, the shaft 6 of the sinker is pushed over the barbs 9 of the needles and under the extension portion 16 of the plates 13 so that the shaft becomes located between the notches 17 and closes the barbs 9. When a large needle bed is used as shown in FIG. 10, the shaft 6 of the sinker is also located in notches (not shown), similar to the notches 17, in the intermediate depressor plate 26. The old loops already at the base of the plastic needles are then pulled over the closed barbs, the shaft of the sinker 6 removed and then the old loops pulled over the new loops just formed so that the new loops become linked with the old loops. The material is then pulled down onto the shanks of the needles so that the new loops are passed beneath the points of the needle barbs. The device is then reloaded as described above except from the other end of the needle bed.
Referring now to FIGS. 5 and 6, an alternative to using the shaft of the sinker to close the barbs of the needles is to provide a separate depressor bar 25. In this case, after the loops have been formed on the needles, the bar 25 is pushed with the thumbs away from the bases of the needles and, guided by rebate 18, comes to rest on the barbs 9 of the needles. Forcing the bar 25 into notches 17 then forces the barbs 9 into the needle recesses 11 whereupon the old loops may be pulled over the new ones as before.
A needle 2 itself has several distinct advantages over a conventional needle e.g.
i. the needles are made of a flexible plastics material preferably nylon which allows the needles to flex sideways as shown in FIG. 9 and to be placed somewhat closer together than would be the case if the needles were rigid. If rigid needles were used, sufficient gaps between each needle would have to be provided to allow the yarn to be drawn from between the needles by the hook 4 of the sinker and thus a bed using rigid needles would be longer than the bed using the same number of plastic needles.
ii. the needles have a bend opposite the barbs which has two purposes:
a. during the twirling operation, when the yarn is travelling into the needle bed, it flows up the bed by the base and therefore the yarn stays fairly close to the shafts of the needles and away from the points of the barbs which would otherwise have a tendency to foul it.
b. during the fabric pulling-off operation, the force of the finished material on the downward projecting tips of the needles tends to push the needles upwardly slightly against the shaft of the sinker (or the depressor bar). Therefore the bend closes any of the barbs which might be open a little too far.
iii. The flexibility afforded by plastics materials allows the barbs 9 to be depressed with very little force and thereby permits the shaft 6 of sinker 1 to be used in place of the heavy presser bar usually found in knitting devices of this type. | A knitting device has a needle bed consisting of a plurality of equidistantly spaced parallel needles and a sinker the needles being held between two depressor plates which form location points for a locking bar which in use closes the barbs of the needles when the sinker has picked up a row of stitches by movement along the needle bed so that said row of stitches can be moved to the bottom of the needles to form a row of stitches in a knitted article. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Statement of the Technical Field
[0002] The present invention relates to the field of computer software and speech recognition and more particularly to user-navigated dynamic voice portals that use speech recognition technology.
[0003] 2. Description of The Related Art
[0004] Contrary to visual applications, voice-based applications have the problem that for input recognition no strict pattern matching can be used. The nature of speech recognition makes it very difficult to distinguish between terms having similar pronunciations. Therefore, during the design of speech applications, care should be taken to provide input choices which are pronounced as differently as possible, so as to avoid the problem of recognizing the wrong choice.
[0005] The problem of recognizing the wrong input choice in a speech recognition application occurs with voice portals, which are generally built by various parties that may not be aware of the terms used in the various applications disposed within the voice portal. Often, a voice portal will have, in addition to the current grammars (or commands) for the actual choice to be made, additional active grammars, such as certain “universal” grammars that allow a user to navigate through the portal, e.g. a command such as “go back.” Thus, at any given moment, a combined set of grammars are active, and the voice recognition engine has to search in the set of combined active grammars for a match.
[0006] A problem arises if the various grammars used across the various applications on the portal are designed by different parties, as is the case for voice portals built on a general portal architecture, such as the IBM WebSphere™ Portal Server. General portal architecture allows for new applications to be added dynamically by an administrator. The new added choices created by each new application modify the available choices in a selection menu, and thereby affect the quality of recognition. Generally, the administrators are not voice technology specialists, and may further have to operate a voice portal in multiple languages. Because of this, there is always a risk that a new voice application may drastically reduce the quality of the portal.
[0007] FIG. 1 depicts an example of a sample content and organization of a voice portal. The user is generally presented with a tree 10 , into which, after logging into the portal, the user starts at a home directory 11 . The tree then divides into new sub-directories 12 and 14 , for “Business” and “Entertainment”, respectively. At home directory 11 , the user would be presented with two choices, for “Business” or “Entertainment,” which would be the current grammars for the choice that the portal would need to recognize. In addition to those current grammars, there may be additional active grammars, such as “go back” or “quit.” As the user navigates deeper into the menu 10 , the current grammars may change from one menu selection step to another. After the “Places” menu selection step 60 , the user would proceed to the “Pages” step 65 , and would be presented with a new set of menu options 16 , 17 , 81 , and 19 , labeled “Information,” Notes, “Directory,” and “Sports,” respectively. The new menu options would be added to the set of active grammars.
[0008] Below these menu options are the various portlets or voice applications in the applications phase 70 at the bottom of the menu. Applications 20 , 22 , 24 each branch off from menu item 16 , while applications 40 , 42 , and 44 each branch off from menu item 18 . The two sets of voice applications may have been written and arranged by different parties not knowing which terms the other party used for the title of each application. Within each branch of applications additional grammars would be added to the active set which the speech recognition engine of the portal must recognize.
[0009] In menu 10 , it can be seen that application 34 is titled “Directory,” which is the same as menu option 18 . If the grammar for selecting menu option 18 is active within the selection choice following menu option 17 , then the system would have trouble distinguishing between identically pronounced terms. Similarly, if a universal grammar such as “store settings” was also active, this would present recognition problems if the user were to navigate through menu item 18 , which has the application named “Stores.”
[0010] Currently, the only way of testing a portal's recognition quality after setting up the portal or installing a new voice application (or portlet) is to call into the system and check manually, or by user testing with a human user, how well the system works. This can be time-consuming and expensive. It would be desirable therefore, to provide a quality evaluation tool that assesses the ability of a voice portal to recognize different terms in the various applications attached to the portal, by analyzing and measuring the similarity of the terms.
SUMMARY OF THE INVENTION
[0011] The present invention addresses the deficiencies of the art with respect to evaluating the quality of voice input recognition by a voice portal and provides a novel and non-obvious method, system and apparatus for evaluating the quality of voice recognition by dynamic voice portals.
[0012] In a method of evaluating the quality of voice input recognition by a voice portal, a current grammar is extracted from the voice portal. A test input is generated for the current grammar. In this regard, the test input includes a test pattern and a set of active grammars for the current grammar. The test input can be entered into the voice server and the test pattern can be analyzed against the set of active grammars with a speech recognition engine in the voice server. Consequently, a measure of the quality of recognition for the current grammar can be derived.
[0013] Systems consistent with the present invention include a system for evaluating the quality of voice input recognition by a voice portal. An analysis interface extracts a set of current grammars from the voice portal. A test pattern generator generates a test input for each current grammar. The test input includes a test pattern and a set of active grammars corresponding to each current grammar. The system further includes a text-to-speech engine for entering each test pattern into the voice portal. A results collector analyzes each test pattern entered into the voice portal with the speech recognition engine against the set of active grammars corresponding to the current grammar for said test pattern. A results analyzer derives a set of statistics of a quality of recognition of each current grammar.
[0014] Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated in and constitute part of the this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
[0016] FIG. 1 is a block diagram illustrating an exemplary voice portal;
[0017] FIG. 2 illustrates a voice portal with a system arranged in accordance with the principles of the present invention for evaluating the quality of voice input recognition by the voice portal; and
[0018] FIG. 3 is a flowchart showing the process of evaluating the quality of voice input recognition by a voice portal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The present invention is a method and system for evaluating the quality of voice input recognition by a voice portal. The invention works by collecting a set of grammars for one or more voice applications disposed in a voice portal and testing the ability of the voice portal to recognize a particular grammar from among the set of other grammars that may be active with the particular grammar being tested. A measure of quality of recognition can be derived for each grammar, thereby enabling the voice portal to be reconfigured to allow for better voice input recognition.
[0020] FIG. 2 illustrates a voice portal with a system arranged in accordance with the principles of the present invention for evaluating the quality of voice input recognition by the voice portal. The overall integrated system 100 can include a voice portal having a portal server 105 and a voice server 110 . The portal server includes a voice aggregator 107 and one or more voice applications or portlets 108 . The voice server can also include a text-to-speech (TTS) engine 114 and a signal manipulator 112 . To this overall system 100 , the present invention couples an analysis interface 120 to the portal server 105 , a test pattern generator 125 , a result collector servlet 130 , a grammar and dependencies collector 140 and grammar database 145 , a measurements results database 150 , and a results analysis unit 152 which produces one or more reports 155 .
[0021] The portal server 105 can be voice-enabled through coupling to a voice server 110 . The voice server 110 is the unit with which an outside caller directly communicates, and can be linked to a telephone network or some other communications network. The voice aggregator 107 is the software that manages the various voice applications 108 running on the portal server 105 . When a user communicates with the voice portal, the voice aggregator presents the user with a menu, such as the menu in FIG. 1 , wherein the user can select voice applications and content from a variety of selections, and can also navigate through the menu and the various voice applications 108 . Each command that a user enters into the voice portal is a grammar which the voice server 110 must recognize to send an appropriate command to the portal server 105 .
[0022] The analysis interface 120 exposes external entities to the logic of the voice aggregator 107 and allows the grammar and dependencies collector 140 to collect the various grammars enabled in the voice portal. The grammar database 145 and measurements results database 150 can be one or more data storage media or devices. The signal manipulator 112 can be any signal processing component that emulates the influence of different telephone or communications network qualities, such as line length, crosstalk, or noise, that is applied to the output of the TTS generator 114 . The TTS 114 and manipulator 112 can be separated from the voice server 110 or can be integral to the voice server 110 .
[0023] As used herein, a “current grammar” shall mean any grammar that is on the system of the voice portal, and can be any one of the grammars that corresponds to the various menu options for: (i) navigating through the voice portal, and (ii) selecting one of the portlets 108 on the portal server 105 . The core idea of the invention is to check all current grammars in a voice portal with an automatic mechanism, so as to assess the capability and quality of voice recognition of the voice portal.
[0024] FIG. 3 is a flowchart showing the process of evaluating the quality of voice input recognition by a voice portal. In this process, the present invention first provides for an analysis interface 120 software to be coupled to the voice portal and with the portal server 105 . The analysis interface 120 communicates with the voice aggregator 107 to extract and retrieve any and all current grammars, at step 210 . Since portal servers like portal server 105 are most likely implemented as a web application, the grammar and dependencies collector 140 could send one or multiple HTTP requests through analysis interface 120 to collect the current grammars, as well as the dependencies between the grammars. A database 145 can be used to store the data.
[0025] The test pattern generator 125 software can select a grammar from the set of current grammars stored in database 145 , as well as the other grammars dependent on the selected grammar. A dependent grammar is any other grammar that may be executed by a user at any given aggregation step when navigating through the menu of the voice portal. Taking the menu in FIG. 1 as an example, if the user had navigated to menu item 17 for “Notes”, the voice aggregator 1 . 07 could present a set of “active” grammars to a user at that stage, being the grammars for each of the portlets 30 , 32 , and 34 , for “Projects”, “Meetings” and “Directory”, respectively, the grammars for the other menu options 16 , 18 , and 19 , for “Information”, “Directory” and “Sports”, respectively, and the navigational grammars, such as “go back” or “quit.” Therefore, as used herein, for any given current grammar which may be selected by the test pattern generator 125 , the set of “active” grammars are all other grammars that may be presented to the user, including the selected current grammar, at the stage in the voice portal where the user may enter a command corresponding to the selected current grammar.
[0026] For each selected current grammar, the test pattern generator 125 creates a “test input” for the grammar, at step 220 . The test input can include both a test “pattern” and a set of active grammars corresponding to the current grammar for which the test input and test pattern is generated. The test pattern can be the actual word or term for the current grammar, or may also include additional words, terms, or sounds. The test pattern can also be entire sentences or phrases. Thus, the test input can include one or more test patterns that incorporate the selected current grammar in some way.
[0027] The test pattern generator 125 thus generates a test input for each current grammar and also aggregates a set of active grammars corresponding to the current grammar for each test input. The test input can be a VXML document having the test patterns and set of active grammars incorporated therein.
[0028] The test input is then entered into the voice server at step 230 . The test pattern itself is entered through the TTS engine 114 and signal processor 112 into the voice server 110 . The signal processor 112 can manipulate the sound of the test pattern by emulating the effects of different user voices, different languages, varying communications network qualities, and other modifications of the sound signature of the test pattern. Both TTS engine 114 and signal manipulator 112 may be separate units outside of the voice portal, in which case the synthesized output of the two units could be connected to the voice server 110 through some communications network. Or, the TTS 114 and signal manipulator 112 may already be integrated within the voice server 110 . The set of active grammars corresponding to the current grammar for which the test pattern is generated is entered into the voice server 110 through a separate channel, such as from the results collector servlet 130 , and may be done through the VXML test document described hereinabove.
[0029] Once the test pattern is entered into the voice server 110 , in step 240 , a speech recognition engine in the voice server can be used to obtain an assessment of how well the voice portal recognized the test pattern. The quality of the recognition of the test and the current grammar being tested by the test input is therefore obtained. This quality of recognition can be monitored and collected by the results collector servlet 130 and stored in the measurements results database 150 . The quality of recognition can include a set of statistics that are generally used to assess the quality. Two examples of such statistics are the confidence level and n-best results, which generally used by speech recognition engines. Thus, the set of statistics can include a confidence level and a set of n-best results for the test input for each grammar tested, and resulting the confidence level and set of n-best results for the test input can be compared with an expected value for each metric to assess the quality of recognition.
[0030] In step 250 , the process determines whether the quality of recognition is acceptable. If the quality is not acceptable, system 100 can be used to adjust and modify the selected current grammar, re-execute the test phase by running through steps 210 , 220 , 230 and 240 , and re-assess whether the quality of recognition is acceptable. If the results are found to be acceptable at step 250 , the process terminates.
[0031] An example of the process of the method of the present invention can be illustrated using the voice portal menu 10 of FIG. 1 . To test the quality of recognition of menu item 34 for “Directory”, the test input having a test pattern including the word “Directory” can be generated. When the current grammar for menu option 34 for “Directory” was extracted, the set of active grammars would also have been created. If the system on the voice portal is configured to have the grammars activated at all times for all directories in the Places 60 and Pages 65 levels of menu 10 , as well as certain grammars for navigational commands like “Go back” and “Quit”, the set of active grammars for the current grammar for portlet 34 for “Directory” would be: {“Business”, “Entertainment”, “Information”, “Directory”, “Sports”, “Projects”, “Meetings”, “Directory”, “Go Back”, “Quit”}. A test pattern of “Directory” could be recognized by the speech recognition engine in the voice portal by assigning confidence levels to each grammar in the set of active grammars. A theoretical example of such confidence levels are listed below in Table 1.
TABLE 1 Grammar Confidence Level “Business” 0.21 “Entertainment” 0.10 “Information” 0.32 “Directory” 0.98 “Sports” 0.28 “Projects” 0.26 “Meetings” 0.35 “Directory” 0.99 “Go Back” 0.08 “Quit” 0.12
[0032] Confidence levels of close to one are regarded as a near perfect match, whereas confidence levels of near zero are regarded as not a match. If more than one grammar in the set of active grammars were to produce very high confidence levels, each above a certain pre-determined threshold, then the quality of recognition could be assessed as poor, since the system could incorrectly recognize one grammar for another. This can be seen in the example set above, where the two grammars for “Directory” each produce confidence levels that are far above any other of the grammars. The voice portal would therefore recognize one of the two grammars having the high confidence level. But it would not be able to distinguish between the two. Thus, the system would show that the quality of recognition is low in that the voice portal would not be able to easily distinguish between two grammars for two different commands. Hence, the user's ability to navigate through the portal would be compromised.
[0033] The present invention therefore provides a method and system for evaluating the quality of voice input recognition by a voice portal. The present invention can execute a test of the voice portal very quickly, at relatively low cost, and with far greater ease than a human system administrator of a voice portal could otherwise do. The present invention could test all grammars in a system, even if the grammars were spoken in different languages, and even if a voice portal system administrator does not know the languages. Furthermore, because of the ability of TTS engines to render different voices (male, female, fast, slow . . . ), the present invention can utilize the TTS engine to test the voice portal with a much more robust input, than a human administrator can otherwise do. Also, because of a speech recognition engine's more fine-grained ability to characterize the similarity of two sounds, while a human system administrator could only determine whether a voice portal simply worked or did not work, the present invention can measure how much one sound differs from another to produce a more detailed assessment of the quality of recognition by a voice portal.
[0034] The present invention can be realized in hardware, software, or a combination of hardware and software. An implementation of the method and system of the present invention can be realized in a centralized fashion in one computer system, or in a distributed fashion where different elements are spread across several interconnected computer systems. Any kind of computer system, or other apparatus adapted for carrying out the methods described herein, is suited to perform the functions described herein.
[0035] A typical combination of hardware and software could be a general purpose computer system with a computer program that, when being loaded and executed, controls the computer system such that it carries out the methods described herein. The present invention can also be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein, and which, when loaded in a computer system is able to carry out these methods.
[0036] Computer program or application in the present context means any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following a) conversion to another language, code or notation; b) reproduction in different material form. Significantly, this invention can be embodied in other specific forms without departing from the spirit or essential attributes thereof, and accordingly, reference should be had to the following claims, rather than to the foregoing specification, as indicating the scope of the invention. | A method and system for evaluating the quality of voice input recognition by a voice portal is provided. An analysis interface extracts a set of current grammars from the voice portal. A test pattern generator generates a test input for each current grammar. The test input includes a test pattern and a set of active grammars corresponding to each current grammar. The system further includes a text-to-speech engine for entering each test pattern into the voice server. A results collector analyzes each test pattern entered into the voice server with the speech recognition engine against the set of active grammars corresponding to the current grammar for said test pattern. A results analyzer derives a set of statistics of a quality of recognition of each current grammar. | 6 |
RELATED APPLICATIONS
This application is a divisional of pending U.S. patent application Ser. No. 13/769,079, filed Feb. 15, 2013, and titled “Natural Gas to Liquid Fuels,” which is a continuation-in-part of pending U.S. patent application Ser. No. 13/472,793, filed May 16, 2012, and titled “Gas to Liquid Fuels,” the disclosures of which are hereby incorporated by reference herein in their entirety.
BACKGROUND
The oil and gas industry is faced with the need to produce more fossil energy or to prove that the production of such energy is possible. Efforts expended heretofore in this regard have, among other things, revealed that a considerable amount of fossil energy may be obtained from shale deposits, which were previously thought to be only barriers to the migration of subterranean hydrocarbons. Rather recently it has been learned that many of the same shales, whose only function was thought to serve as a caprock or impermeable barrier to subterranean hydrocarbon migration, in fact, have served as massive agents to absorb natural gas. This natural gas can be converted to commercial production. Following drilling and fracturing the shale, so much of this type of unconventional gas production has been proven up at this point in time that the supply has exceeded the demand and prices of natural gas have diminished significantly.
Many operators who have paid the cost to drill, such as operators in the Barnett Shale in the area of Fort Worth, North Texas, have shut in their successful shale gas wells because the market price of the gas has fallen below acceptable economic levels for the operation of such wells. Therefore, there is a need to enhance the natural gas market and thereby encourage added drilling aimed at improving the natural gas reserves.
Gas to Liquid (GTL) technology for converting natural gas, which consists primarily of methane, to a liquid fuel has existed for nearly a century. A recent resurgence of interest is providing significant advancements in the rapidly growing art. Prior art teaches that natural gas may be converted to higher molecular weight hydrocarbons by generally two techniques, either a direct transformation with an intermittent step of creating a synthesis gas (syngas) or a gas composed generally of hydrogen and carbon monoxide.
Direct transformation into higher molecular weight hydrocarbons may occur through pyrolysis, during which methane generally at 250° C. to 100° C. is passed through a catalyst in the absence of substantial amounts of oxygen. Processes and catalysts are described in U.S. Pat. Nos. 4,199,533; 4,547,607; 4,704,496; 4,801,762; 5,093,542; 5,157,189; and 5,245,124. These processes require high activation energy and can be difficult to control. As a result, there is minimal commercial use of direct GTL processes.
Two or three GTL processes where the natural gas is first converted to syngas have more prevalent commercial use than the direct processes. For example, Mobil has developed M-gasoline which is created by a three stage process. Natural gas is converted to syngas which is transformed into methanol which is finally made into M-gasoline. However, the most common GTL process is a two stage process in which the natural gas is first converted to syngas which is then changed into liquid hydrocarbons via the Fischer-Tropsch process.
SUMMARY
The embodiments described herein are based upon a process that first removes sulfur compounds from natural gas, and then converts the processed gas using a catalyst-aided process to a liquid that is useable for transportation or other fuel. This process may be performed in a relatively small unit that could be portable, skid mounted, and/or located adjacent to a source of the natural gas. The liquid to which the natural gas is expected to be converted is anticipated to be a sulfur free mixture of various fuels: for example, gasoline, diesel fuel, jet fuel, and light bunker fuel. This mixture of fuels may then be separated to render them commercially saleable. Therefore, a third process involves the use of a small skid-mounted fractionation tower to separate and stabilize the various fuel products.
The skid-mounted conversion unit and processing equipment may be readily moved to any location where fuel is needed and where the gas can be piped to the skid. In an alternative embodiment, the skid may be placed at natural gas supply location, such as at a gas wellhead, pipeline, storage facility, or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a top view of one embodiment of an apparatus comprising a heavy duty truck trailer with a gas to liquids (GTL) conversion unit for transforming natural gas into a liquid phase at ambient temperature and pressure.
FIG. 2 is a side view of one embodiment of the apparatus of FIG. 1 .
FIG. 3 is a cross-section of one embodiment of a Fischer-Tropsch reactor.
FIG. 4 illustrates an alternative embodiment of a portable GTL apparatus.
FIG. 5 illustrates a hydrogenation unit and Fischer-Tropsch reactors according to one embodiment
FIG. 6 illustrates an alternative embodiment of a hydrogenation unit and Fischer-Tropsch reactors
FIG. 7 illustrates an apparatus for holding catalyst within a hydrogenation unit and/or Fischer-Tropsch reactor pipe or tube.
DETAILED DESCRIPTION
The invention now will be described more fully hereinafter with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. One skilled in the art may be able to use the various embodiments of the invention.
The embodiments disclosed herein relate generally to a method and apparatus for converting sulfur-free natural gas to a non-cryogenic liquid for storage and/or transport by land vehicle to another location or for conversion to a motor fuel on-site. A large number of stranded gas fields exist, meaning that they are not close enough to a pipeline to be economically feasible for production. As a consequence, such fields may not be economically developed and the economic value of the gas remains trapped in the earth's crust. Oil wells on the other hand can be developed even if such wells are in a remote location because the liquid oil may be accumulated in a designated tank placed at the well location and then transferred to a refinery by a tanker truck. In some cases, natural gas may be available at a remote location, for example, in a pipeline. However, such natural gas has greater utility if converted in situ to a liquid motor fuel.
The apparatus may comprise at least one truck trailer, a desulfurizing unit, a gas to liquid conversion unit for transforming natural gas into hydrocarbon, characterized by having a liquid phase at atmospheric pressure and ambient temperature, said gas to liquid conversion unit on top of said truck trailer and fastened thereto. A natural-gas-driven electric generator sufficient to provide electricity for all requirements of the truck trailer and the equipment mounted on the truck trailer may also be provided on the truck trailer.
FIG. 1 is a top-view illustration of an apparatus comprising at least one heavy-duty truck trailer 100 with a gas to liquids (GTL) conversion unit for transforming natural gas into a liquid phase at ambient temperature and pressure according to one embodiment. FIG. 2 is a side view of the apparatus. The GTL conversion unit is designed and outfitted for filtering, desulfurizing, dehydrating, and regulating the pressure of the gas and liquid processed by the apparatus. The gas to liquid conversion unit comprises a first stage reactor 103 for converting the effluent of pipeline quality gas into synthesis gas by a hydrogenation source, such as a steam methane reformer, hydrogen generator, hydrogen tank, or auto thermal reformer, and a Fischer-Tropsch reactor 104 for polymerizing said synthesis gas to produce said liquid hydrocarbon.
The gas to liquid conversion unit of the apparatus is characterized by having catalyst sites that are designed and arranged with high surface-area to volume ratios.
The gas to liquid conversion unit comprises a gas preprocessing section for filtering, desulfurizing, dehydrating, and regulating the pressure of said unit. A first stage converts the effluent of said gas preprocessing unit into synthesis gas by a hydrogen generation process or source, such as a steam methane reforming reaction. Thereafter, the gas is conducted through a Fischer-Tropsch reactor to polymerize said synthesis gas to produce liquid.
The apparatus further comprises one or more storage tanks into which the liquid fuels emanating from a fractionation tower may be temporarily stored until they are delivered to a collection tank truck.
In one embodiment, a method for converting natural gas at remote terrestrial sources to hydrocarbon is characterized by having a liquid phase at atmospheric pressure and ambient temperature, comprising the steps of moving the trailer mounted GTL equipment in close proximity to the gas source, coupling the equipment to the gas source, and conducting natural gas through the gas to liquid conversion unit while located near said source.
Referring to FIG. 1 , the apparatus comprises a natural gas inlet 101 that may be coupled to a natural gas source, such as a natural gas well or a pipe line. Natural gas flows through the inlet 101 to a sulfur gas removal unit 102 , which is loaded with iron shavings in one embodiment. The natural gas flows over the iron filings in desulfurization unit 102 , which removes the sulfur content from the natural gas. The removal of sulfur from the natural gas improves the lifetime of the catalysts, such as that used in the Fischer-Tropsch reactions. For sulfur in the form H 2 S, the iron shavings react with the sulfur in the natural gas to form FeS 2 . Depending on the content of the sulfur in the natural gas source any other suitable desulfurization unit 102 that is adapted to remove sulfur from natural gas may be used.
The output of sulfur gas removal unit 102 is provided to a hydrogenation unit 103 , such as a steam methane reformer that is loaded with a Nickel catalyst. In other embodiments, any hydrogen source generator may be used in place of a steam methane reformer, such as a hydrogen generator, an auto thermal reformer, or a tank of commercially available hydrogen gas.
The output of hydrogenation unit 103 is input to Fischer-Tropsch reactors 104 . In the case where a steam methane reformer is used as hydrogenation unit 103 , the Fischer-Tropsch reactors 104 will cause the methane molecule to act as follows: CH 4 +H 2 O→CO+3H 2 . The reactant products are converted from natural gas to a liquid as the substance passes through the Fischer-Tropsch reactors 104 . The long chain hydrocarbon molecules structure produced by the Fischer-Tropsch reactors may vary depending on the hydrogen source selected.
A cross section of one embodiment of Fischer-Tropsch reactor 104 is shown in FIG. 3 . Fischer-Tropsch reactors 104 comprise sections of 1″ extra heavy (XH) line pipe 301 wrapped around a 16″ lightweight center pipe 302 . The 1″ XH line pipe may be loaded with Ruthenium catalyst to effect a Fischer-Tropsch reaction. In other embodiments, a Cobalt catalyst or any other suitable catalyst that will effect a Fischer-Tropsch reaction may be used. Ambient air may be circulated through the 16″ pipe 302 to control the system temperature. In other embodiments, the pipes 301 in the Fischer-Tropsch reactor 104 may be arranged in other configurations that allow air to circulate for cooling. The Fischer-Tropsch reactors 104 may be air cooled using any method of air generation including, for example, high velocity fans. Additionally, water may be used as a coolant and may enhance the reactant process.
The Fischer-Tropsch reactors 104 may be positioned at an angle (e.g., at a 3° slope) to cause the liquid to flow through the reactors toward a fractionation tower 105 . The output of Fischer-Tropsch reactors 104 passes through a gas trap (not shown). Any gases trapped in the gas trap are recirculated to the front of the Fischer-Tropsch reactors 104 for further GTL processing. A back-pressure control valve 106 is positioned on the pipe linking the Fischer-Tropsch reactors 104 to the fractionation tower 105 in order to control the pressure, flow rate and temperature into fractionation tower 105 . In one embodiment, fractionation tower 105 may be hinged or otherwise adapted to be rotated from a vertical position for transport of the apparatus in order to avoid low hanging structures or wires.
By the time the reactant products reach the base of the fractionation tower 105 , the reactant products are hot liquids capable of boiling and, as such, the products will be segregated as they cool in the fractionation tower 105 . Fractionation tower 105 may have a number of outlets, such as an outlet 107 to a gasoline storage tank, an outlet 108 to a diesel storage tank, an outlet 109 to an aviation fuel storage tank, and an outlet 110 to a heavier fuel storage tank.
FIG. 4 illustrates an alternative embodiment of a portable GTL apparatus 400 . The GTL equipment is mounted on a truck trailer, skid, pallet, or other portable or mobile platform 401 that allows it to be moved and deployed near natural gas sources, such as gas wellhead, pipeline, storage tank, or other location or facility. The portable platform 401 may be driven, dragged, pushed, airlifted, floated, or otherwise moved to a natural gas source in any location whether easily accessible or remote. A desulfurization unit 402 has an inlet 403 that may be coupled to the natural gas source. Desulfurization unit 402 may use iron filings, for example, to react with and remove sulfur from the natural gas. The natural gas output from desulfurization unit 402 is fed by pipe 403 to a hydrogenation unit 404 .
The desulfurized natural gas passes through a hydrogenation unit 404 from input 405 to output 406 . In one embodiment, hydrogenation unit 404 comprises twenty-nine 1″ pipes 407 surrounding a 16″ central pipe (not shown). The twenty-nine 1″ pipes contain a Nickel catalyst that reacts with the natural gas to generate hydrogen (H 2 ) molecules. The natural gas and hydrogen is provided to two Fischer-Tropsch reactors 408 by pipe 409 . In other embodiments, hydrogenation unit 404 may be, for example, a steam methane reformer, an auto thermal reformer, or a hydrogen tank that generates or provides hydrogen to mix with the natural gas.
The natural gas and hydrogen enter the Fischer-Tropsch reactors 408 at inputs 410 . In one embodiment, Fischer-Tropsch reactors 408 each comprise twenty-nine 1″ pipes 411 surrounding a 16″ central pipe (not shown). The twenty-nine 1″ pipes contain a catalyst, such as Ruthenium or Cobalt, that effect a Fischer-Tropsch process so that the natural gas and hydrogen is converted to liquid at exits 412 . The Fischer-Tropsch reactors 408 are constructed at an angle, such as a 3° angle, so that the liquid will flow from input 410 toward output 412 .
The liquid is then provided by pipe 413 to a fractionation tower 414 . The liquid rises in fractionation tower 414 and is output at a port 415 selected depending upon the desired liquid fuel type. A valve 416 on pipe 413 may be used to regulate the pressure output from Fischer-Tropsch reactors 408 and input to fractionation tower 414 .
It is expected that the temperatures created in hydrogenation unit 404 and the Fischer-Tropsch reactors 408 will be very high. For example, a hydrogenation unit 404 using a Nickel catalyst as described above may operate at approximately 800° C. and the Fischer-Tropsch reactors 408 may operate at approximately 300° C. Therefore, hydrogenation unit 404 and the Fischer-Tropsch reactors 408 will likely require cooling. In one embodiment, hydrogenation unit 404 and the Fischer-Tropsch reactors 408 are air-cooled by an air source 417 , such as a fan, blower, or turbine that provides air to the center 16″ pipe of the hydrogenation unit 404 and the Fischer-Tropsch reactors 408 via air pipes 418 . The air flows though the center pipe to cool the respective hydrogenation unit 404 and/or the Fischer-Tropsch reactor 408 . The cooling air exits the hydrogenation unit 404 and the Fischer-Tropsch reactors 408 via exhaust 419 .
FIG. 5 illustrates the hydrogenation unit 404 and Fischer-Tropsch reactors 408 according to one embodiment. A central 16″ pipe receives air at input 502 from an air source. Twenty-nine 1″ pipes 503 are wrapped around the center pipe 501 . Catalyst, such as Nickel in a hydrogenation unit 404 or Ruthenium or Cobalt in a Fischer-Tropsch reactor 408 , is placed in the twenty-nine pipes 503 . Any other catalyst proven to affect the desired reaction(s) may be used in the alternative. An input manifold 504 distributes the incoming natural gas (hydrogenation unit 404 ) or natural gas and hydrogen (Fischer-Tropsch reactors 408 ) to the twenty-nine pipes 503 . An output manifold 505 collects the output natural gas and hydrogen (hydrogenation unit 404 ) or liquid (Fischer-Tropsch reactors 408 ) and provides the output to pipes 409 or 413 , respectively, at outlet 506 . Cooling air exits the assembly via outlet 507 .
FIG. 6 illustrates an alternative embodiment of the hydrogenation unit 601 and Fischer-Tropsch reactors 602 . Instead of wrapping the 1″ pipes around a center pipe for cooling as illustrated in FIGS. 1 , 4 , and 5 , the 1″ pipes 604 are held in bracket-like structure 600 that provides spacing between the 1″ pipes 604 so that air can flow between the pipes 604 for cooling. An air source 605 , such as fans, blowers, or turbines, is used to provide ventilation through the bracket structure 600 and across pipes 604 for cooling.
It will be understood that other cooling arrangements, such as water cooling, may be used for the hydrogenation unit and Fischer-Tropsch reactors depending upon the configuration of the system. Additionally, it will be understood that the embodiments illustrated herein are merely examples and that the number of pipes, other pipe sizes and other configurations may be used for the hydrogenation unit and Fischer-Tropsch reactors.
FIG. 7 illustrates an apparatus for holding catalyst within a hydrogenation unit and/or Fischer-Tropsch reactor pipe or tube. Each device, as illustrated above, comprises a plurality of pipes filled with a catalyst. Over time, the catalyst will become “poisoned” as other compounds bond to its active surface sites, which reduces the usefulness of the catalyst. When that occurs, the catalyst in the hydrogenation unit and/or Fischer-Tropsch reactor will need to be replaced. In order to simplify the replacement of the catalyst within the pipes 701 of these devices, a tray 702 is adapted to carry the catalyst 703 . This makes it easier to load, unload, and replace the catalyst. The operator simply has to load the catalyst 703 on the tray 702 and inserts the tray 702 into a pipe 701 of the hydrogenation unit or Fischer-Tropsch reactor (e.g., pipes 301 ( FIG. 3 ) or 503 ( FIG. 5 )).
The catalyst 703 may have any appropriate form that is required by the process or available from a manufacturer, such as pellets, disks, rings, or other shapes. Tray 702 may be adapted to hold a particular form of the catalyst in a desired position, for example, to maximize an available surface area exposure or to generate turbulence or to otherwise improve the desired reaction. Tray 702 may also be adapted to evenly distribute the catalyst in pipe 701 and to prevent unwanted shifting of the catalyst during movement of the GTL apparatus. In one embodiment, trays 702 extend the entire length of the pipe 701 and provide for easy loading and uniform flow of hydrogen over the catalyst 703 in order to maximize contact with the catalyst and provide uniformity of reaction.
In other embodiments a series of trays 702 may be used in a pipe 701 instead of a single long tray.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized that such equivalent constructions do not depart from the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention. While preferred embodiments of the invention have been described, modifications and adaptations of the preferred embodiments will occur to those skilled in the art. It is to be expressly understood that modifications and adaptations are in the spirit and scope of inventions set forth in the following claims. | A method and apparatus for converting natural gas from a source, such as a wellhead, pipeline, or a storage facility, into hydrocarbon liquid stable at room temperature, comprising a skid or trailer mounted portable gas to liquids reactor. The reactor includes a preprocessor which desulfurizes and dehydrates the natural gas, a first stage reactor which transforms the preprocessed natural gas into synthesis gas, and a liquid production unit using a Fischer-Tropsch or similar polymerization process. The hydrocarbon liquid may be stored in a portable tank for later transportation or further processed on site. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/823,449, filed Aug. 24, 2006, entitled: RANDOM CHANNEL ASSSIGNMENT IN A WDM-BASED PON by inventor Frank J. Effenberger [Attorney Docket No. 683440.0029].
FIELD OF INVENTION
[0002] The present invention generally relates to optical network systems, and more specifically, relates to Wavelength Division Multiplexing (WDM) based passive optical networks (PONs).
BACKGROUND OF THE INVENTION
[0003] A passive optical network (PON) includes a passive optical power splitter/combiner that feeds individual branching fibers to end users. The PON also has a tree topology that maximizes coverage with minimum network splits, thus reducing optical power loss. In addition, a common fiber feeder part of a PON is shared by all optical network units (ONUs) WITH terminating branching fibers. Moreover, traffic sent downstream from an optical line terminal (OLT) at a local exchange is simply broadcast by an optical power splitter to every ONU. Sending traffic from an ONU upstream to a local exchange, however, requires accurate multiple access techniques in order to multiplex collision-free traffic generated by the ONUs onto the common feeder fiber.
[0004] At least four major categories of multiple access techniques for fiber have been developed. These techniques include: Time Division Multiple Access (TDMA), SubCarrier Multiple Access (SCMA), Wavelength Division Multiple Access (WDMA), and Optical Code Division Multiple Access (OCDMA).
[0005] In a WDM-PON network, each ONU uses a wavelength channel to send packets to an OLT at a local exchange. In addition, the wavelength channel constitutes an independent communication channel and may carry a different signal format from other wavelength channels carried by other ONUs connecting to the OLT.
[0006] Conventionally, a WDM-PON network is designed to make each hardware unit at each endpoint, as well as each wavelength selective multiplexing element in the network, tune to a unique wavelength. This design works for wavelength independent power splitting PONs. However, a network with such a design is difficult to manage and prone to errors. One of conventional ways to improve performance of such a design is to implement “colorless” end-point equipment. In a colorless WDM-PON network, an ONU has no intrinsic channel assignment. The ONU obtains a channel assignment by virtue of what fiber the ONU is attached to on the network. This typically assumes that the network uses a WDM device as a splitting element. The physical effects used in this type of network design are either injection locking of a broadband laser source, or reflective modulation of downstream light.
[0007] However, these conventional schemes for WDM-PONs are not ideal to provide a complete solution for prevention of errors. Furthermore, because a WDM device is required in such a network design and all PONs currently deployed use a wavelength independent power splitter, these schemes require PON reconstruction.
[0008] Therefore, there is a need to develop a WDM scheme that operates over a power splitting PON infrastructure that does not require wavelength selected ONUs.
SUMMARY OF THE INVENTION
[0009] The present invention discloses a system for a WDM based PON network in which the system randomly assigns each ONU channel. When ONUs are manufactured and shipped to the field for implementation, a uniform but random distribution of channel assignment is maintained. As these ONUs are connected to the network, each channel is loaded in a random process.
[0010] The present invention also discloses a “selectionless ONU” scheme in a WDM based PON network. In the selectionless scheme, each ONU may transmit virtually any wavelength bands in upstream signal transmissions. This scheme may be accomplished by arranging receivers adjacent to each other in an OLT of the network. As a result, each receiver's sensitivity waveband may be immediately adjacent and cross over with another adjacent receiver's sensitivity waveband. Thus, the OLT electronics may be able to receive and recover signals from each ONU.
[0011] Therefore, in accordance with the previous summary, objects, features and advantages of the present disclosure will become apparent to one skilled in the art from the subsequent description and the appended claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
[0013] FIG. 1 is a WDM based PON system according to the present invention;
[0014] FIG. 2 depicts adjacent channel scheduling of a selectionless ONU scheme in a WDM based PON system according to the present invention;
[0015] FIG. 3 depicts channel spacing of the selectionless ONU scheme in a WDM based PON system according to the present invention; and
[0016] FIG. 4 depicts ONU channel discovery of the selectionless ONU scheme in a WDM based PON system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present disclosure can be described by the embodiments given below. It is understood, however, that the embodiments below are not necessarily limitations to the present disclosure, but are used to describe a typical implementation of the invention.
[0018] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments. It is understood that several modifications, changes and substitutions are intended in the foregoing disclosure and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
[0019] Now referring to FIG. 1 , a WDM based PON ( 100 ) according to the present invention is illustrated. Network ( 100 ) includes an OLT ( 110 ), a power optical splitter ( 130 ), and a plurality of ONUs including ONU ( 121 ), ONU ( 122 ), ONU ( 123 ), and ONU ( 129 ). As shown in FIG. 1 , ONU ( 121 ), ONU ( 122 ), ONU ( 123 ), and ONU ( 129 ) connect to power optical splitter ( 130 ) via optical fibers. Power optical splitter ( 130 ) connects to OLT ( 110 ) via another optical fiber. OLT ( 110 ) further includes an Arrayed Waveguide Grating (AWG) Router ( 115 ), a MAC logic unit ( 111 ), and a downstream Transmitter ( 119 ), and a plurality of upstream receivers including Receiver ( 112 ), Receiver ( 114 ), Receiver ( 116 ), and Receiver ( 118 ). A person of ordinary skill in the art will understand, downstream signals may be served by N WDM channels, and upstream signals may be served by M WDM channels. Both N and M can be any small integer. In addition, OLT ( 110 ) may possess N downstream transmitters and M upstream receivers. However, each ONU, including ONU ( 121 ), ONU ( 122 ), ONU ( 123 ), and ONU ( 129 ), may contain only one downstream receiver and one upstream transmitter.
[0020] In conventional designs, wavelength assignment to an ONU is fixed by virtue of the design—that is, each unit operates on a particular pair of channels that can not be changed. In addition, each downstream channel uses a multiplexing scheme such that multiple ONUs can share the downstream channel. Moreover, each upstream channel uses a multiplexing scheme such that multiple ONUs can share the upstream channel. There are several such schemes that are based on TDMA or CDMA schemes, including ITU B-PON (G.983.x), ITU G-PON (G.984.x), and IEEE 802.3ah systems. These schemes are all electronic and multiple identical ONUs sharing a channel are coordinated and configured automatically under stored program control.
[0021] The present invention provides that random channel assignment to an ONU. As ONUs are manufactured and shipped to the field, a uniform but random distribution of channel assignment is maintained. As each ONU is connected to the network ( 100 ), each of the channels are loaded in the random process. Practically, the impact of random loading is small and manageable. Additionally, the cost of the random channel assigned ONUs is not much more than conventional non-WDM ONUS, and the OLT cost is the same as non-WDM OLTs. Therefore, a significant savings over other WDM schemes can be achieved.
[0022] An example that further illustrates this embodiment of the present invention will now be described. Consider a Gigabit PON (G-PON) based network, where a non-WDM system supports 64 ONUs per PON, using the 1480 to 1580 nm band for downstream communications and the 1260 to 1360 nm band for upstream communications. Using a conventional coarse WDM (CWDM) grid of wavelengths, it is possible to construct economical transceivers that use 20 nm spaced wavelength channels. Therefore, if the existing 100 nm wavelength bands are divided into five 20 nm bands, a network according to the present invention may be implemented where downstream channels may equal upstream channels (N=M=5). On average, each channel pair may have 64/5 which is approximately 13 ONUs. Understanding that a PON may be loaded with 64 ONUs, there is usually less than 16 ONUs sharing a channel pair 90% of the time, and there is usually less than 20 ONUs sharing a channel pair 99% of the time. In practice, PONs are usually not loaded to ultimate capacity. Therefore, chances of exceeding this design rule may even be lower. Even in rare cases when this design rule is exceeded, the only consequence may be marginally lower performance for the ONUs in the crowded channel pair, and this will probably not cause a failure of service.
[0023] In one embodiment, the present invention provides an arrangement wherein each downstream channel may associate with a single upstream channel. In this embodiment, the number of channel pairs may equal to the number of downstream channels. In another embodiment, the present invention provides ONUs that have random pairings of upstream and downstream assignments. This additional randomization may require OLT's management of an entire multi-PON system, but may reduce chances of having less capacity in both directions in the system.
[0024] The present invention also provides an embodiment with a WDM-PON system where downstream communication may use a single high-speed channel and upstream communication may use multiple, slower channels. In another embodiment, the system uses high speed (such as 10 Gbit/s) channels, in downstream communication because downstream communication has only one single transmitter operating continuously. In contrast, upstream communication has multiple transmitters that operate in burst mode. This complicates transmission and makes lower speeds more practical. Hence, this embodiment illustrates a scheme providing a single downstream channel and multiple upstream channels to balance aggregate capacity of both downstream and upstream communication in the system.
[0025] A WDM-PON system designed according to the present invention may use well defined wavelength bands, with pass-bands and guard-bands for signal transmission. In downstream communication, a conventional design may be used. However, in upstream communication, the present invention allows each ONU to transmit at virtually any wavelength. Therefore, the need to select ONU lasers into wavelength bands is eliminated. This scheme is called the “selectionless ONU” scheme.
[0026] In the selectionless ONU scheme designed according to the present invention, each receiver's sensitivity waveband is immediately adjacent and crosses over with the adjacent receiver's wavebands. FIG. 2 illustrates adjacent channel scheduling of selectionless ONU scheme ( 200 ) in a WDM based PON system according to the present invention. Scheme ( 200 ) includes a plurality of OLT receivers, including Receiver ( 212 ) and Receiver ( 214 ); four receiver's channels, Channel ( 222 ), Channel ( 224 ), Channel ( 226 ), and Channel ( 228 ); and three ONUs, ONU ( 232 ), ONU ( 233 ), and ONU ( 234 ). In this embodiment, ONU ( 232 ) transmits signals in Channel ( 222 ). Thus, only Receiver ( 212 ) receives signals from ONU ( 232 ). Similarly, ONU ( 234 ) transmits signals in Channel ( 224 ). Therefore, only Receiver ( 214 ) may receive signals from ONU ( 234 ). Also shown in FIG. 2 , ONU ( 233 ) may transmit signals in a crossover portion of Channel ( 222 ) and Channel ( 224 ). Accordingly, both Receiver ( 212 ) and Receiver ( 214 ) may receive signals from ONU ( 233 ). In this embodiment, no matter what wavelength an ONU uses, corresponding light for the ONU can be received by one receiver if the ONU transmits in a wavelength at the center of a channel, and possibly two receivers if the ONU transmits in a wavelength at the edge of a channel. In either case, OLT electronics may be able to receive signals from either ONU.
[0027] The selectionless ONU scheme of the present invention allows upstream channel overlap to be scheduled in order to avoid interference between adjacent channels. As illustrated in FIG. 2 , ONU ( 232 ) is on the center of Channel ( 222 ). Therefore, signals from ONU ( 232 ) are received only on Receiver ( 212 ), and thus members of the Receiver ( 212 ) reception group. Similarly, ONU ( 234 ) is on the center of Channel ( 224 ). Accordingly, signals from ONU ( 234 ) are received only on Receiver ( 214 ), and thereby members of the Receiver ( 214 ) reception group. However, ONU ( 233 ) is on the edge of Channel ( 222 ) and Channel ( 224 ). Consequently, signals from ONU ( 233 ) are received on both Receiver ( 212 ) and Receiver ( 214 ), and therefore members of both Receiver ( 212 ) and Receiver ( 214 ). In this latter case, the OLT should coordinate schedules of PONs such that members of any reception group do not transmit at the same time. For example, Receiver ( 212 ) and Receiver ( 214 ) should not transmit signals simultaneously.
[0028] The selectionless ONU scheme of the present invention also allows the use of inexpensive ONU transmitters that may vary in wavelength by about 10 nm over temperature and time. FIG. 3 illustrates channel spacing of a selectionless ONU scheme ( 300 ) in a WDM based PON system according to the present invention. The scheme ( 300 ) includes three ONUS, including ONU ( 302 ), ONU ( 304 ), and ONU ( 306 ); and four Receiver channels, including Channel ( 312 ), Channel ( 314 ), Channel ( 316 ), and Channel ( 318 ). In this embodiment, ONU ( 302 ) transmits signals corresponding only to Channel ( 312 ). ONU ( 304 ) transmits signals mostly corresponding to Channel ( 314 ), but sometimes to Channel ( 316 ). In addition, ONU ( 306 ) transmits signals mostly corresponding to Channel ( 318 ), but sometimes to Channel ( 316 ). In this embodiment, the OLT monitors and controls all ONUs wavelength drifting using a non-deterministic wavelength hopping scheme. In another embodiment, OLT receiver wavelength scheduling is devised such that an ONU may stay in one group consistently. This may be achieved by spacing the receiver's channel bands wide enough so that the ONU wavelength variation is less than a stop band separating non-adjacent channels. This embodiment is designed so that the difference from the highest wavelength of Channel ( 312 ) and the lowest wavelength of Channel ( 318 ) is set to be 10 nm, and the ONU wavelength variation is 10 nm, to ensure that the ONU may not change group membership over time.
[0029] The selectionless ONU scheme according to the present invention also allows discovery of ONU group membership to ensure proper signal transmission from each ONU to the OLT. FIG. 4 depicts ONU channel discovery of selectionless ONU scheme ( 400 ) in a WDM based PON system according to the present invention. Scheme ( 400 ) illustrates ONU channel discovery at an initial time (T=0) and at a later time (T=later). When ONU ( 402 ), ONU ( 404 ) , or ONU ( 406 ) is first connected (T=0) to the network and activated, ONU ( 402 ), ONU ( 404 ), or ONU ( 406 ) begin to transmit signals during special intervals of time specifically reserved for the OLT to discover ONUs. At this time, the OLT may inspect upstream receivers to see which receiver is receiving upstream light. If two adjacent receivers receive light from a particular ONU, both Channel ( 414 ) and adjacent Channel ( 416 ) receive light from ONU ( 404 ), then ONU ( 404 ) can be assigned on the edge between Channel ( 414 ) and Channel ( 416 ). In this embodiment, Channel ( 412 ) receives light from ONU ( 402 ), and Channel ( 418 ) receives light from ONU ( 406 ), then ONU ( 402 ) may be provisionally placed in a receiver's group corresponding to Channel ( 412 ), and ONU ( 406 ) may be provisionally placed in a receiver's group corresponding to Channel ( 418 ). However, over time, the ONUs might drift in wavelength, and be carried into either channel edge, or into an adjacent channel. FIG. 4 illustrates that at a later time (T=later), ONU ( 404 ) drifts to Channel ( 414 ), and ONU ( 406 ) drifts to the edge between Channel ( 416 ) and Channel ( 418 ). In this case, the OLT may provisionally re-assign ONU ( 404 ) to the receiver's group corresponding to Channel 414 , and the OLT may re-assign ONU ( 406 ) to be on the edge between Channel ( 414 ) and Channel ( 416 ).
[0030] The previous description of the disclosed embodiments is provided to enable those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art and generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | A wavelength division multiplexing based passive optical network is disclosed. The network includes an optical line terminal; a power optical splitter connecting to the optical line terminal by an optical fiber; and several optical network units. Each of the optical network units connects to the power optical splitter by each of other optical fibers by a random process. | 7 |
This application claims priority under 35 U.S.C. §119(e) to U.S. provisional application Ser. No. 61/362,216, filed Jul. 7, 2010, the entire disclosure of which is incorporated by this reference into the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to deployable wind turbine systems incorporating used and discarded shipping containers or similar elements.
2. Description of Related Art
Wind turbines are used for energy generation worldwide, and consist of a rotary engine in which the kinetic energy of a moving fluid is converted into mechanical energy by causing a bladed rotor to rotate. Some bladed rotors are oriented along a vertical axis (Vertical Axis Wind Turbines (VAWT)), and some are oriented along a horizontal axis (Horizontal Axis Wind Turbines (HAWT)). Some turbines are installed for use on a fixed site, and some are portable.
The ATOPIA RESEARCH Inc. document titled PITCH_AFRICA LOG 3, 3.2 SPECIAL CONTAINERS (April-June) describes various types of specially fitted out shipping containers that make possible the provision of services in areas without basic amenities.
SUMMARY OF THE INVENTION
One primary aspect of the invention concerns a portable, selectively deployable wind turbine including a bladed rotor attached to a pole or mast. The mast, which can be telescoping, and the bladed rotor can be stored within a container for shipping and erected for operation. The lower support mast is preferably attached to a guide rail or track that sits at the base of the container with a tractor element and hinge, provided by way of a ball or pin-joint, such that the base of the lower support mast can be moved along the track as the head of the mast, i.e. the upper support mast, is raised out of the container to its erect position. The upper mast is linked to the lower mast and can be extended either as the lower mast is being erected or after the lower mast has been erected. An A-frame support, a v-brace, a v-strut or “vang,” or some other relatively rigid support element is attached to the storage container or a reinforcing frame received in the storage container and to the lower mast such that it assists in erecting the mast. Struts of the A-frame support are attached to the container or reinforcing frame and to the mast in such a way as to constrain the mast to move in an arc as the traction mechanism is operated to move the foot of the mast along the track.
Tsunamis, earthquakes, hurricanes, and other disasters often strike unexpectedly, yet the scale of the devastation inflicted during and in the wake of these events is not always random. Preparedness and disaster management plans can play a critical role in reducing human suffering and mortality caused by such disasters. While the nature of the required preparedness varies depending on the type of the disaster, the needs of the afflicted areas during post-disaster relief and recovery periods are often similar: shelter, energy for first aid and critical functions, clean water and food, and medical assistance.
The Haiti earthquake (2010) was a sad illustration of the shortfalls of post-disaster relief efforts related to the logistical challenges of organizing and transporting aid. One such shortfall addressed by the subject matter of the present invention is the lack of systems to reliably generate electricity for first aid and critical functions. Gas or diesel powered generators are usually used, but these items require a constant supply of fuel that can be difficult to ensure and expensive to deliver, since transportation routes are often in very poor conditions after a disaster. These generators, moreover, often compete for scarce fuel with essential transportation needs. Better alternatives are possible, and the hybrid wind power system forming the subject matter of this invention, built into a shipping container, can be rapidly deployed in disaster areas without the need for a significant fuel supply. It is contemplated that the version disclosed here should be able to generate around 5 kW of power; the maximum power could be higher if the arrangement is deployed in a windy area. The system would also have a storage capacity of several days.
Electricity production and storage would be sufficient to power a clinic, a small hospital, or a school. In the particular embodiment disclosed, a vertical axis turbine on a telescoping mast is utilized. Meteorological sensors can be embedded in the system to characterize wind and solar resources at the location and analyze and optimize the performance of the system. Such a power generation and storage unit will also promote sustainable practices in designing post-disaster engineered systems and will serve as a prototype for renewable energy development during a post-disaster rebuilding phase, allowing the local populations to become more familiar with these renewable technologies.
Wind turbines generate static and dynamic loads in the structure that have been analyzed and included in the design. The invention provides mechanisms utilized to deploy the wind turbine that are simple to allow easy erection with minimum human intervention and power, and permits all parts to retract back to fit inside the container, making deployment over different types of terrain possible.
According to one particularly preferred embodiment of the invention, the portable, selectively deployable power supply and storage arrangement includes a substantially rigid frame, a floor securable to the substantially rigid frame and having a longitudinally extending guide member provided thereon, a mast assembly having a first end pivotally connected to a tractor element slidable along the guide member and a second end opposite the first end, and a wind turbine receivable at the second end of the mast assembly. A support is pivotally connected to and extends between both the substantially rigid frame and a portion of the mast assembly so that, upon displacement of the tractor element along the guide member, the support produces movement of the mast assembly between retracted and deployed positions. Batteries or other energy storage elements, which may be supported by the frame, can be included in the assembly to store energy provided by output current produced during operation of the wind turbine. In order to facilitate transportation and relocation of the power supply and storage arrangement in an advantageous manner, the substantially rigid frame, the floor, the mast assembly, the wind turbine, and the support are configured so as to define a single unit and are collectively receivable as that unit in a shipping container.
Multiple height adjustable outrigger arrangements preferably are attachable to the shipping container to stabilize the arrangement when the arrangement is in use and, at the same time, receivable within the container during transportation of the arrangement when the arrangement is not in use.
The mast assembly is most preferably telescopic, with an upper support mast defining the second end retractable into a lower support mast defining the first end for reception in the shipping container. A display facilitating identification of the arrangement, by power output rating or otherwise, may be disposed on the shipping container.
A process of relocating a selectively deployable power supply and storage arrangement is also described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a collection of elements according to the invention received, in a packed condition, within a standard, readily available shipping container.
FIG. 2 illustrates the collection of elements shown in FIG. 1 but without the shipping container.
FIG. 3 shows elements of the overall arrangement when the mast assembly of the invention has been placed into its substantially vertical, erect position.
FIG. 4 is a lateral view of the overall arrangement showing the mast assembly in the substantially vertical, erect position but with portions of the mast and the container cut away.
FIG. 5 shows various elements of the arrangement as they appear when the wind turbine utilized is deployed for use.
FIG. 6 is a view illustrating positions occupied by elements shown in FIG. 5 when those elements are in a packaged condition.
DETAILED DESCRIPTION OF THE INVENTION
The isometric view provided by FIG. 1 shows a collection 48 of elements received, in a packed condition, within a standard, readily available 40′ ISO (International Organization for Standardization) shipping container 20 . The packaged collection 48 of elements is utilized in a manner to be described to place a vertical axis turbine 50 ( FIG. 3 ) into operational condition. The container 20 is entirely conventional, and, as illustrated in FIGS. 1 and 6 , includes a pair of end walls 22 , 24 , a pair of side walls 26 , 28 , a floor 30 , and an open top 32 .
FIG. 2 illustrates the collection 48 of elements without the shipping container 20 . This collection 48 has numerous individual components, including a steel reinforcing frame 52 , a perforated sheet steel floor 54 , floor reinforcing and support rails 56 , producing a raised floor level within the container 20 providing space for cabling and other services, a tractor element guide member, such as a guide rail 58 , secured to the floor 54 , a tractor element 60 slidable along the guide rail 58 , and a mast assembly, having a lower turbine support mast 62 interconnected by a hinge 64 to the tractor element 60 and a tubular element 66 defining an upper support mast that telescopes into and out of the lower turbine support mast 62 . The telescoping mast can use hydraulics or a manual or motor driven pulley system. Openings 68 may be included in the lower support mast 62 for weight reduction and/or servicing purposes.
The legs of a rigid A-frame support or “vang” 70 are illustrated in FIG. 3 as pivotally connected, by hinges or otherwise, to both the steel reinforcing frame 52 and to an appropriate portion of the lower support mast 62 . During displacement of the tractor element 60 to the right from its left end position on the guide rail 58 shown in FIG. 2 , the A-frame support 70 forces the lower support mast 62 to pivot about the hinge 64 from the substantially horizontal, packaged position shown in FIG. 2 to the substantially vertical, erect position shown in FIG. 3 . An appropriate stop 112 ( FIG. 5 ) on or adjacent to the guide rail 58 could be used to preclude movement of the tractor element 60 beyond its preferred position on the guide rail when the lower support mast 62 is in the erect position. Upon displacement of the tractor element 60 back to the left, of course, the A-frame support 70 forces the lower support mast 62 from the position it occupies in FIG. 3 back into the substantially horizontal, packaged position shown in FIG. 2 . Movement of the tractor element 60 along the guide rail 58 may be produced in any appropriate manner, such as a manually operated or motorized screw drive (not shown).
Multiple outrigger arrangements 72 , illustrated by way of example in FIG. 3 , are used to stabilize the container 20 in position whenever the turbine arrangement received in the container 20 is in use. Each of these outrigger arrangements includes a plurality of solid or tubular support members 74 interconnected in such a way as to define frames that secure height adjustable feet 76 to the opposite side walls 26 and 28 of the container 20 . Bolts (not shown) extending through holes (not shown) formed in the container walls 26 and 28 may be used to removably secure ends of some of the support members 74 to the side walls 26 and 28 , while brackets 78 are used to interconnect the height adjustable feet 76 to outer ends of the outrigger arrangements 72 . FIG. 3 also shows an ornamental display 80 that could be used to facilitate identification of the overall collection 48 of elements by power output rating or in some other way.
When the outrigger arrangements 72 and other elements of the collection 48 of elements are stored in the packed condition shown in FIG. 1 , bands or straps 82 may be used to secure the support members 74 in position within the shipping container 20 . Bolts 84 or other fasteners may be passed through the perforations in the floor 54 to secure the feet 76 in place in the packed condition.
Shelving 86 is visible in each of FIGS. 1-3 . This shelving 86 is mounted on panels 90 welded or otherwise secured to the reinforcing frame 52 , and may be used, for example, to receive a pair of opposed arrays of energy storage elements, such as batteries 88 , utilized to selectively supply power as needed and to store energy produced by the wind turbine in a manner to be described. The shelving can be configured to protect the batteries from exposure to rain. Additional power generating systems such as solar panels could be attached to the structure to harvest additional power or run equipment.
In the particular arrangement illustrated in the drawing figures, a VAWT 92 , including two blades 96 interconnected to a drive element 94 by diagonal spars 98 , is disposed at a distal end of the tubular element 66 defining the upper support mast. The drive element 94 is rotatable relative to the tubular element 66 due to the action of wind on the blades 96 . When the wind turbine 92 is to be used, the blades 96 are mounted in or moved into their operational positions, shown in FIG. 3 , and locked into place. FIGS. 1 and 2 show the positions of the blades 96 in the packed condition. Other wind turbine configurations could be used if desired, although any turbine used would need to be properly storable whenever the overall collection 48 of elements is placed into the packed condition. Any such turbine could either be adjusted and designed to fit in the container, folded or hinged such that it can fit into the available space of the container, or partially dismantled to fit into the available space.
FIG. 4 is a lateral view of the overall arrangement showing the lower support mast 62 in the substantially vertical, erect position of FIG. 3 but with portions of the mast 62 and the container 20 cut away. While outrigger arrangements 72 are not shown in FIG. 4 for simplicity, the VAWT 92 as shown is in its deployed position, and the tubular element 66 defining the upper support mast, the A-frame support 70 , the drive element 94 , one of the two blades 96 , and one of the diagonal spars 98 are identified. FIG. 4 shows a sleeve 102 with reinforcing ribs 100 secured by way of a collar 104 to the distal end of the lower support mast 62 . The sleeve 102 operates as a guide for the upper support mast as it moves between its extended and retracted positions. The rotor of a conventional electromagnetic generator 106 , mounted at the lower end or the element 66 , is interconnected by a drive shalt (not shown) to the drive element 94 so that the rotor spins as a result of wind forces acting on the blades 96 . Output current from the generator 106 is passed by a cable 108 (shown partially cut away) to an inverter 110 , and then supplied by cable connections (not shown) to respective batteries 88 for storage.
FIG. 5 shows various elements of the arrangement as they appear when the VAWT 92 is deployed for use. In addition to the stop 112 and the guide rail 58 mentioned previously, outrigger arrangements 72 and blades 96 are identified in FIG. 5 . These same elements are identified in FIG. 6 , which illustrates positions taken by the same elements in the packaged condition.
The container used for the erectable mast and turbine can be of any scale; for example, a large 40′ shipping container or a smaller, 20′ shipping container could be utilized. The container serves to provide structure, ballast, and foundation for the wind turbine while in operation, as well as permitting storage for structural attachments necessary to stabilize the mast and turbine when they are erected or in operation. The container operates as a storage container and housing for all electrical and mechanical components needed to operate the system including, for example, batteries for energy storage, generators, inverters, and alternators, and as protection during transport and storage. The deployable wind turbine arrangement thus acts as a mobile battery power unit that can be stored in ports or other types of sites and delivered to areas that need an emergency power supply or independent power source. Many shipping containers are dumped in places of the world or are underutilized in ports, and these containers could be converted for additional use in regions where there is a need for power. There is a need, as well, for demonstrating sustainable power generation technologies, such as small wind, to communities in the world to facilitate the spread of knowledge about such technologies as long-term systems for providing energy.
The upper and lower mast sections are typically made from hollow steel or aluminum sections or trusses, but bamboo or composites, such as carbon fiber or fiberglass, could be used as well. The electrical and mechanical components necessary for the turbine to function can be installed within the lower mast or the upper mast, or outside of those masts in the base of the container or at the top of the mast adjacent to the wind turbine.
The tractor element 60 slidable along the guide rail 58 may be operated manually or electronically with a motor. This tractor element can attach to the guide rail or track using a system of pulleys, rollers, wheels or other types of bearings conducive to the loads and motion.
The bank of batteries stored in the container stores power which can be received and delivered as either AC or DC. These batteries 88 can be pre-charged prior to the wind turbine system being deployed and can be topped up as if power is used by the wind turbine. Alternatively, the batteries can operate as a storage mechanism for surplus energy. The batteries also act as structural ballast at the base and sides of the container to contribute to its stability when operating.
A range of systems could be used for distributing the power produced by the turbine. The turbine can be used to distribute power directly at its location for running equipment such as tools, refrigeration of medicines, and the charging batteries, or it can be used to distribute power remotely by attaching transmitting cables from the central unit to remote locations. A power system has thus been developed that addresses power needs emergency situations such as those following environmental or other crises, and can supply power to assist in aid operations.
The invention is particularly suitable for use as a portable, off-grid power supply arrangement utilizing wind power, as it incorporates a deployable mast and an integrated electrical power storage system. The invention is thus particularly suitable for rapid post-disaster deployment.
While one particular form of the invention has been illustrated and described, it will be apparent that various modifications and combinations of the invention detailed in the text and drawings can be made without departing from the spirit and scope of the invention. For example, references to materials of construction, methods of construction, specific dimensions, shapes, utilities or applications are also not intended to be limiting in any manner and other materials and dimensions could be substituted and remain within the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims. | A portable, selectively deployable power supply and storage arrangement includes a frame, a floor securable to the frame and having a longitudinally extending guide member provided thereon, a mast assembly having a first end pivotally connected to a tractor element slidable along the guide member and a second end opposite the first end, and a wind turbine receivable at the second end of the mast assembly. A support is pivotally connected to and extends between both the frame and a portion of the mast assembly so that, upon displacement of the tractor element along the guide member, the support produces movement of the mast assembly between retracted and deployed positions. To facilitate transportation and relocation of the power supply and storage arrangement, the frame, the floor, the mast assembly, the wind turbine, and the support are configured to define a single unit and are collectively receivable in a shipping container. | 8 |
FIELD OF THE INVENTION
This invention relates to semiconductor processing and, more particularly, to semiconductor processing wherein the dopants are placed into the semiconductor by ion implantation.
BACKGROUND OF THE INVENTION
Silicon molecular beam epitaxy (MBE) is a technique for low temperature growth of single crystal silicon epitaxial layers in an ultra-high vacuum station. One system that has been used for silicon MBE processing is disclosed by Y. Ota in the article entitled "Silicon Molecular Beam Epitaxy with Simultaneous Ion Implant Doping," Journal of Applied Physics, Vol. 51 (2), February 1980, pp. 1102-1110. In the Ota system, a high purity source of silicon is evaporated by an electron beam and the evaporated silicon deposits as single crystal epitaxy on a heated silicon substrate. In order to create devices that are useful, the silicon epitaxy is usually doped with p-type or n-type impurities. In the Ota system, an ion gun generates ions of the required dopant and this dopant is coupled through a drift chamber to the growth chamber in which the silicon deposition takes place. As a result, very low energy dopant ion implantation is coincident with the process of growing an epitaxial layer. By using ion implant doping the number of stray dopant atoms is reduced from other prior art techniques wherein the dopant was simply evaporated in order to deposit on the growing substrate. Fewer dopant atoms are introduced into the growth chamber because the sticking coefficient of the implanted dopant is much higher than that of an evaporated dopant. An additional advantage in ion implant doping is that the dopant ion beam density can be monitored and controlled during the epitaxial growth.
In the system disclosed by Ota, arsenic ions from an arsenic plasma are developed by the ion gun and propelled through the drift chamber to the growing epitaxial substrate thereby establishing an n-type dopant in the silicon substrate. There is no suggestion in the Ota article as to how one might establish a p-type dopant in the growing epitaxial layers. One technique that would be apparent to those skilled in the art is to simply terminate growth of the epitaxial structure while a different plasma consisting of a p-type dopant is established in the ion gun. It is desirable that growth should be suspended for a minimal length of time when converting from one dopant source to another since when growth is suspended, ambient oxygen, carbon and other contaminants accumulate on the sample surface thereby providing a source of crystalline disruption for any subsequent epitaxial growth. These defects in the crystal structure are known to impair the operation of the semiconductor device and also to result in a decreased minority-carrier lifetime. It is therefore desirable to change from one type of conductivity to another in as short a period as possible with as little disruption in growth as possible.
SUMMARY OF THE INVENTION
This invention is based on the discovery that a mixed plasma can be created in the ion gun with ions from elements that result in opposite conductivities. By using a method described hereinafter, a plasma can be created in the ion gun with ions of both arsenic and boron simultaneously present in the plasma. As a result, a mass analyzer present at the output of the ion gun can be used to rapidly select either arsenic or boron as the ions to be implanted in the scanned regions (either layers or areas) of the growing silicon epitaxial layer.
The present inventive method can be practiced in the apparatus previously disclosed by Ota. In this apparatus a silicon source is evaporated by an electron gun in order to deposit single crystal on a heated silicon substrate. Doping is accomplished by coupling the ions from a low energy ion gun through to the growing silicon epitaxial layer. A plasma of boron ions is first established in the ion gun by admitting BF 3 gas to the ion chamber which is ionized by electrons emitted from the hot filament contained therein. The B + species of ion current is monitored and maximized by adjusting the gas pressure. After the system has had time to stabilize, a solid arsenic charge is moved into the ion gun into closer proximity to the hot filament. Insertion of the arsenic probe is done very slowly in a stepwise manner to allow gradual heating of the arsenic. If the arsenic charge is inserted too rapidly, the B + species of ion will vanish. The arsenic ion current can be detected with an appropriate setting of the mass analyzer and final beam optimization is accomplished by again adjusting the BF.sub. 3 gas inlet pressure. The mass filter can then be adjusted to select one of the ions extracted from the plasma and this ion can then be coupled through to the growing silicon epitaxial layer. At any point in time after a predetermined growth with doping using the selected ion, the mass analyzer in the ion gun can be readjusted to select the other ion and growth of a layer with opposite conductivity can be continued in a matter of seconds.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be more readily understood after reading the following detailed description in conjunction with the drawing wherein:
FIG. 1 is a cross sectional view of prior art apparatus that may be utilized to practice the present invention;
FIG. 2 is a cross sectional diagram of the ion source from FIG. 1 when used to practice the present invention; and
FIG. 3 is a plot of ion current versus magnet current in the mass filter showing each of the species of ion generated in the embodiment constructed to practice the present invention.
DETAILED DESCRIPTION
The epitaxial growth system disclosed by Ota in the above-identified article is shown in cross-sectional form in FIG. 1. In this system, an atomically clean silicon substrate 101 is positioned in a growth chamber and resistively heated by power that is externally coupled to the substrate. The growth chamber also includes an 11 kV electron gun 102 that is directed toward a silicon source located 15 cm from the substrate to create a silicon molecular beam 103 that is, in turn, directed toward substrate 101. Liquid nitrogen shrouds surround the e-gun unit and the substrate heating unit. A portion of the silicon molecular beam 103 is deposited onto the silicon substrate 101 and the rest is deposited on silicon beam collectors (not shown). A silicon thickness monitor 104 is positioned to measure the thickness of the deposited silicon. A thermocouple 105 is attached to a reflector located behind the substrate to monitor the substrate temperature. The thermocouple reading is used to measure substrate temperatures below 750 degrees C at which the pyrometric measurement is not accurate.
The ion implantation system consists of two major sections, an ion gun 130 and an ion beam drift chamber 180. The ion gun 130 is a commercially available ion gun which can be purchased from the Colutron Corporation as a model G-2 low energy ion gun system. This ion gun has a stainless steel cavity into which a charge of solid arsenic can be inserted. This stainless steel cavity may also include an encapsulated thermocouple to monitor the cavity temperature and a gas port or tube 132 into which Ota coupled argon gas for the purpose of controlling the arsenic ions. The solid arsenic charge can be inserted into a plasma chamber 133 which is electrically heated, and the resulting ions are coupled through a mass analyzer or mass filter 134 to the output of ion gun 130.
Mass filter 134 contains crossed electrostatic and magnetic fields. Ions are deflected to one side of the filter by the electric field, and to the other side by the magnetic field. Only if the ions pressure the proper ratio of electronic charge to molecular mass will the action of the fields balance, permitting the ions to pass unimpeded through the filter.
The ions out of the ion gun 130 are coupled into the drift chamber 180 where they are deflected by 15 degrees around the bend in the drift chamber by deflection plates designated as 181 in FIG. 1. The mass filter 134 in ion gun 130 is not capable of rejecting non-ionized material and these neutrals are filtered out by the bend because they continue in a straight line and deposit on the walls of the drift chamber. The ion beam deflected by the deflection plates 181 is coupled through high voltage scan plates 183 which can be used to position the selected ion beam on the surface of substrate 101.
As indicated in FIG. 1, Ota used this apparatus to implant arsenic ions into the growing epitaxial layer on a silicon substrate. In accordance with the present invention, the gas port of the tube 132 normally used to couple argon gas into the plasma chamber is instead used to couple boron trifluoride (BF 3 ) into the plasma chamber as shown in FIG. 2. As indicated in FIG. 2, the ionization chamber of the apparatus in FIG. 1 is essentially unmodified, but it is used to generate a plasma containing both B + and As + dopant species. A solid arsenic charge 201 is contained in the hollow end of a moveable stainless steel rod 202. The boron source is BF 3 gas that is 99.5 percent pure. This gas is coupled by way of a tube 132 into the same chamber as the arsenic charge. Initially the arsenic charge is retracted and the arsenic vapor contained in the ionization chamber is at a minimum. Valve 205 is opened to permit the BF 3 gas to flow into the chamber and be ionized by electrons emitted from the hot filament 206 which dissipates about 270 watts. The inlet pressure of the BF 3 gas is adjusted to be about 40-50 millitorr. The pressure in the ionization chamber is somewhat less. An arc discharge is struck when the anode voltage provided by anode supply 210 is equal to about 80-100 volts. The species present in the plasma at this point in time are B + , BF + , F + and BF 2 + as determined by mass analysis. The B + species ion current is monitored and maximized by adjusting the BF 3 gas pressure. The optimal BF 3 inlet pressure has been determined to be about 20-30 millitorr.
After the system has had time to stabilize, the arsenic probe is slowly advanced toward the ionization chamber into closer proximity to the hot filament 206. Simultaneously the anode supply voltage from anode supply 210 is adjusted in order to maintain the plasma discharge. Insertion of the arsenic probe is done very slowly in a stepwise manner to allow gradual heating of the arsenic. When sufficient arsenic vapor pressure has built up in the ionization chamber, an arsenic ion current is detected with the appropriate setting of mass filter 134. Inasmuch as an increase in the As + current is accompanied by a decrease in the B + current, the B + species will vanish if the arsenic charge is overheated. At an optimum setting, the arsenic temperature was determined to be equal to about 300 degrees C. Final beam optimization is accomplished by again adjusting the BF 3 gas inlet pressure. The following table lists typical measured ion beam current for arsenic and boron ion beams by themselves and in combination with plasma of the complimentary species.
______________________________________Species Beam current______________________________________As.sup.+ 218 nAAs.sup.+ (As + BF.sub.3) 110 nAB.sup.+ (BF.sub.3) 58 nAB.sup.+ (As + BF.sub.3) 26 nA______________________________________
The ion extraction voltage provided by power supply 215 was equal to about 1100 volts and the decelerator voltage in the ion gun was set at 500 volts resulting in a final beam energy of about 600 electron volts from the ion gun. The beam currents specified in the table were measured at a target that was placed 130 cm from the exit of the ion gun final lens.
The amount of ion current obtained out of ion gun 130 by varying the magnetic field in the mass filter 134 while maintaining the electric field constant is set forth in FIG. 3. As indicated in FIG. 3, with an electric field potential of 200 volts in the mass filter, an ion current of B + can be obtained by setting the magnet current to 3.3 amps. Similarly, an ion beam of As + can be obtained by setting the magnet unit at 9.0 amps. Accordingly, after the ion beam has been focused and optimized for a particular dopant, the complimentary species may be selected in a matter of seconds merely by adjusting the magnet current in mass filter 134.
The above-described method has been used to construct a bipolar transistor using molecular beam epitaxial growth without any diffusion process. Collector, base and emitter layers were grown on an arsenic doped substrate. The epitaxial structure was doped N + -P-N using the technique described hereinabove. The epitaxial layer with N doping was grown first by coupling the As + ions through to the substrate. The mass filter was then adjusted to select the B + ions and the p-type layer was grown. Finally, an N + layer was grown by readjusting the mass filter to reject the B + ions and select the As + ions.
It should be readily apparent to those skilled in the art that the present invention can be used equally as well to fabricate areas of different conductivity on a substrate surface. The scanning plates 183 of the drift chamber 180 can be adjusted to scan only one area of the substrate surface while the ion of one of the dopants is coupled through the mass filter. Subsequently a different ion can be coupled through the mass filter and the scanning plate 183 in the drift chamber 180 can be adjusted to couple these ions through to a different area of the substrate surface.
In addition, it should also be apparent to those skilled in the art that the dopant sources can be in other physical forms, i.e., both can be gaseous, both solid charges or other combinations, including liquid sources. | A molecular beam epitaxial method of fabricating a semiconductor device is disclosed wherein the dopant is implanted by establishing a plasma containing ions of the dopant and the ions are coupled through a drift chamber to impinge on the growing substrate surface. The plasma formed in the ion gun has ions of boron and arsenic and therefore the dopants selected for implantation can be determined by setting a mass filter present in the ion gun. A change to the dopant of the opposite conductivity type can be accomplished in seconds by simply readjusting the mass filter in the ion gun. | 7 |
FIELD OF THE INVENTION
The present invention relates to a zigzag sewing machine, and more particularly to a sewing machine which includes a memory unit for storing patterns to be combined for stitching to a uniform, and by which hems of the patterns may be continuously stitched with determined constant width.
BACKGROUND OF THE INVENTION
Sport players' numbers are formed on uniforms by stitching hems of the numbers as patterns with predetermined V width by using an embroidery sewing machine used exclusively therefor, and an ordinary sewing machine. When using these sewing machines, considerable skillfulness is required.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a sewing machine which may easily form hem stitches by ordinary operation.
The object of the invention is achieved by a sewing machine which is provided with a static memory device storing a plurality of stitching pattern data, a controlling device including a read-out device which makes available pattern data of stitching patterns selected per each of synchronous pulses of an upper shaft to be generated from the static memory device by a needle position detector, and driving means controlling actuations of a needle bar and a fabric feed device. A continuous hem stitching sewing machine of the invention comprises a memory device storing stitching patterns to be combined with predetermined parts and continuous parts, selecting means of the combined stitching pattern, an amplitude signal detecting means for discriminating whether a forming pattern is at the predetermined part or the continuous part, and lift lever detecting means that allows to form the predetermined part according to selection of the combined pattern being stitched to the continuous part.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart showing selections of patterns in the sewing machine of the invention;
FIG. 2 is a perspective view of the sewing machine provided with an improved device of the invention;
FIG. 3 is an explanatory view of functions of the sewing machine of the invention;
FIG. 4 is an explanatory view of an interior structure of the sewing machine;
FIGS. 5(a)-5(f) are explanatory views of stitching hems of player's numbers as patterns;
FIG. 6 is a view showing lift lever detecting means;
FIG. 7 is a flow chart for explaining operations of the invention; and
FIGS. 8(a)-8(c) are explanatory views showing forming patterns by combination of different portions thereof.
FIG. 9 is a view showing a means for detecting rotational phases of the upper shaft.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the invention will be explained with reference to examples of forming the sport players' numbers on the uniforms.
FIG. 2 shows a perspective view of a sewing machine of the invention. The sewing machine comprises a machine frame 1 that holds a needle 17 so that it may reciprocate vertically and laterally so as to form locked stitches together with a thread loop catching means 28 disposed under a needle dropping hole 18a of a needle plate 16.
A selection device 37 is, as shown in FIG. 3, provided with a pattern selecting means 39 (FIG. 1) actuated by a pattern selection button 38 on a panel. Selection of patterns 1 to 6 is effected by a selection switch of ordinary stitching patterns.
An inversion key 41 inverts the selected pattern.
Further, an amplitude selecting device 42, a feed selecting device 43, an indicating device 44, an increasing device 45 and a decreasing key 46 are provided on the panel. The vibration selecting device 42 selects amplitudes of the needle 17 for an automatic condition and for a manual condition. The feed selecting device 43 selects feeding amount for the automatic condition and for the manual condition. The indicating device 44 indicates determined values of the manual condition. The increasing key 45 and the decreasing key 46 control the determined values of the manual condition.
A key 47 provided on the housing 1, operates to produce reverse stitches specifically required for the straight stitches to prevent the stitches from loosening (or fraying) at the beginning and the end of the stitches. If the key 47 is operated when any pattern other than the straight stitches is stitched, finishing lock stitches are produced for the same purpose as in the case of the straight stitches.
A stopping position selecting key 49 is operated to select a stop of an upper dead point and a stop of a lower dead point of the needle 17.
A pattern re-designation switch 59 is for indicating continuing use of a combined pattern which has been selected in a preceding time for combined stitchings, and it is positioned adjacent to the reverse stitching key 47 to facilitate the stitching operation.
A needle bar 3 is mounted on a machine frame 1 and is vertically movable in connection with the upper shaft 2 which is rotatably mounted (journalled) on the machine frame. Namely, as generally known, the needle bar 3 is slidably inserted into a needle bar support 11 and is fixedly connected to a needle holder 10 which is connected to a needle bar crank 8 by a crank rod 9. The crank 8 is operatively connected to as a balance weight 7 secured to one end of the upper shaft 2 for rotation therewith. The needle bar support 11 is pivotally mounted on a vertical shaft 12 secured to the machine frame 1, and is secured against vertical movement. The needle bar support 11 is connected to one end of a rod 13 which has the other end connected to an arm 15 secured on an output shaft 14a of a stepping motor 14 for controlling the needle position.
A feed dog 19 is mounted on a horizontal feed arm 21 to be driven by the drive shaft 2. The movement of the horizontal feed arm 21 is adjusted by adjusting the angular position of a member 22 fixed to one end of an adjusting shaft 23, which has the other end secured to an arm 24 connected to a crank 26 mounted on the output shaft of a feed control stepping motor 25 by way of a crank 26 and a link 27.
A loop taker 28 serves as needle thread hooking means and is supported rotatably on a machine frame 1 under the needle plate 18. A gear 30 is secured to a lower shaft 29 which is rotated in synchronism with the needle bar 3 by the upper shaft 2, and meshes with a gear 31 fixed integrally with the loop taker 28.
Rotary discs 32 are, as shown in FIG. 9, formed with slits, and mounted on the upper shaft 2. The rotary discs constitute means 34 for detecting rotational phases of the upper shaft device 60 detects rotation of the means 34. A take-up lever 35 is connected to the crank 7 via a link 36.
A reference will be made to a controlling device of the sewing machine.
A pattern memory 49 stores amplitude values and feed amounts of stitching patterns selected by the pattern selecting device 39 in accordance with a pattern to be stitched.
With respect to combined patterns as shown in FIG. 5 respectively, other patterns than a continuous pattern 1 are composed of a pattern a of a predetermined part for bending and connecting with stitches c shown with dotted lines, and a series of stitches b formed by zigzag stitches having constant amplitude continued from the predetermined part, and connected to a central processing unit 50. In the combined patterns, one of them has one predetermined part as shown in FIG. 5, 2 to 4, and the other has two predetermined parts ○a1 and ○a2 shown in FIG. 5, 5 to 6.
The numeral 51 of FIG. 1 shows a lift lever detecting means. As shown in FIG. 6, a presser bar holder 58 is secured on a presser bar 57 which holds a fabric presser foot 56 at its lower part, and a lift lever 52 is rotatably pivoted on the machine frame 1. When the lift lever 52 is turned upwardly, the presser bar holder 58 pushes the presser bar 57 upwardly, accordingly.
The machine frame 1 is provided with a microswitch 53 and a counter (not shown). When the presser bar holder 58 is lifted up by turning the lever 52, the holder 58 contacts at its upper surface to the microswitch 53. The counter is connected to the microswitch 53 electrically for counting actions of the latter, and is connected to the central processing unit 50 so that the counted value is reset at 0 by operation of the pattern selection device 39.
Detecting means 54 of amplitude signal is actuated by selecting the combined pattern, and always follows values of the amplitude signal during forming the pattern, and it issues ON signal when the amplitude values on changing become constant, exceeding two steps.
In response to the ON signal, the central processing unit 50 effects a selection of a pattern having a progressively varied amplitude from a minimum to a maximum or of a pattern having a progressively varied amplitude from a maximum to a minimum. When the selected pattern is stitched, ON signal is absent, and the central processing unit nullify all other stitch pattern while the selected pattern is being stitched.
A selected pattern memory 61 stores data about shapes of the selected patterns and data about control of amplitude and feed thereof.
A drive motor 62 drives the upper shaft 2, and is connected electrically to a controller (not shown) that controls starting, stopping and speed.
A further explanation of the operation of the present embodiment will be made with reference to FIGS. 7 and 8.
The player's number "6" is now formed on the uniform, and is shown with a reference numeral 63 in FIG. 8(a). The mark "6" is stitched at its outline 63a with a predetermined width as seen in FIG. 8. The predetermined width is an amplitude W, and when a width is optional, it is a value in advance stored in the sewing machine memory. When a width is designated, the amplitude selecting device 42, the increasing key 45 and the decreasing key 46 are operated to make the designation. The numerals 1 to 5 in FIG. 8(a) correspond to numbers of patterns to be combined.
For stitching the player's number 63 as the pattern, when the pattern selecting device 39 is operated to select the straight continuous pattern 1, the needle 17 drops at the left side of the pattern 1, and therefore the player's number 63 is brought to meet "A1" at the left side of the straight pattern, and a controller (not shown) is actuated to control stitching of the straight part until the portion "a" of FIG. 8(b). As this portion "a" corresponds to the pattern 3 of FIG. 5, it is selected by the pattern selecting device 39. The sewing machine is driven by the rotation detector 60. When ON signal is output at the determined amplitude value by the amplitude signal detector 54, the continuous part c is stitched. As the pattern 3 has one predetermined part a, the needle stops at the lower dead point of the outside of the pattern.
The lift lever 52 is operated to raise the fabric presser foot 56, and the fabric is met at the outside of the number and is turned by angle α. The fabric foot 56 is dropped, and a counting value "1" is calculated by the lift lever detector 51, by which the central processing unit 50 allows to stitch the predetermined part a.
The controller is operated to stitch the predetermined part a of the pattern 3 and the stitch the continuous part b until a part "b".
Since a corner of a part "b" is the same as the pattern 3, the pattern 3 is selected or input by the pattern re-designation switch 59, and the needle is stopped at the upper dead point as the outside of the needle dropping position. The lift lever 52 is operated to raise the fabric presser foot 56, and the fabric is turned for stitching the predetermined part a and the continuous part b of the pattern 3.
Parts "c" and "d" of FIG. 8(b) are similarly stitched with the pattern 3, and since a part "e" of FIG. 8 is the pattern 2, the pattern 2 is selected and input by the pattern selecting device 39, and the needle is stopped at the lower dead point at the outside of the needle dropping position.
The lift lever 52 is operated to raise the fabric presser foot 56, and the fabric is met at the outline of the number, and is turned about 90°. The controller is operated to switch the predetermined part a and stitch the continuous part b until a part "f". Since the part "f" is the part 2, the pattern 2 is selected or input by the pattern redesignation switch 59 to stitch the predetermined part a and stitch the continuous part b until a part "g". Since the part "g" is the pattern 5, the pattern 5 is selected and input by the pattern selecting device 39.
Since the pattern 5 has two predetermined parts as shown in FIG. 5, a first predetermined part ○a1 is stitched by a selecting input and the needle is stopped at the lower dead point as an outside position "d". The lift lever 52 is operated to raise the fabric presser foot 56, and the fabric is met at the outline of the number and is turned about 90°, and a second predetermined part ○a2 is stitched and the continuous part b is stitched until a part "h".
Since the part "h" is the pattern 5, the pattern 5 is selected to stitch the first predetermined part ○a1 , and the needle is stopped. The lift lever 52 is operated to turn the fabric, and the second predetermined part ○a2 is stitched and the continuous part b is stitched until a part "i". Since the part "i" is the pattern 5, the stitching is carried out on the first predetermined part ○a1 , the second predetermined part ○a2 , and the continuous part b.
Since a part "j" is the pattern 3, the pattern 3 is selected and input by the pattern selecting device 39.
Parts k, 1, m, n, and o are all the pattern 3, and the selecting input switch or the pattern re-designation switch is operated to form stitches in succession. Coming to the starting point Al, the finish-up is ordered by the finish-up button and the hem stitching is accomplished as seen in FIG. 8(c). With respect to an inner part of the number pattern, if a starting point A2 is prepared on the straight line, stitching may be performed similarly as the outside stitching.
Since an outside of the inner part is arc shaped, stitching is started at a position A2 in a direction of an arrow C of FIG. 8(b). Therefore, when the pattern selecting device 39 is operated to select a straight continuous pattern 1, the needle is positioned at the left side of the amplitude of the pattern 1, and the fabric is brought to a predetermined position and is stitched until the straight portion of a part "p". Since the position "p" has two predetermined parts as seen in FIG. 5, 5, the pattern 5 is selected and input by the selecting input device 39. The first part ○a1 is stitched and is stopped at an outside part "d". The lift lever 62 is operated to turn the fabric and the number mark 90° clockwise, and the fabric presser foot 56 is brought down. The lift-up detecting means is thereby calculated, and the central processing unit allows to stitch the second predetermined part a2 .
The second predetermined part ○a2 is stitched and the continuous part b is stitched until the straight part of a part "q". Since the corner of the part "q" is the pattern of FIG. 5 5, the pattern 5 is selected by the selecting device 39, and similarly the first predetermined part ○a1 and the second predetermined part ○a2 stitched, and then the continuous part b is stitched until the straight part of a part "t". Since the corners of parts "t" and "s" are both the pattern 5, the stitching is carried out until the part A2 of FIG. 8.
The above mentioned operation takes place when the outside stitching follows the stitching direction B, and the inner side stitching follows the stitching direction C. With respect to the cases when the outside stitching moves in a direction opposite to the direction B and the inner side stitching moves in a direction opposite to the direction C, a reverse key is operated before selecting the patterns, so that patterns may be formed on opposite side of combined patterns shown in FIG. 5. | A sewing machine for and a method of stitching a mark of a predetermined shape onto a fabric, in which the mark is stitched onto the fabric by selective employment of stitch patterns stored in a memory device of the sewing machine and wherein selected patterns form a single pattern of stitches corresponding to the predetermined shape of the mark. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to U.S. Provisional Patent Application No. 61/934,838 filed Feb. 2, 2014, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
This disclosure relates generally to a shirt garter (also known as a shirt stay). More specifically, this disclosure relates a shirt garter that extends around the crotch region of the wearer and is designed for use with a camisole or other shirt-type garment.
BACKGROUND
Shirt garters (stays) are used to hold the wearer's shirt in place (i.e., tucked in) and are generally made of an elastic strap that connects the bottom of the wearer's shirt to the socks or feet. Because these shirt stays extend along the wearer's leg, they can only be worn with full length pants and/or socks and cannot be worn with skirts, dresses, crop pants, shorts, etc. The bulk and design of these shirt stays makes them difficult to remove/adjust when needed by the wearer. Also, because they are usually constructed from an elongated elastic band, they are frequently visible through/under lightweight fabrics. Accordingly, a need in the art exists for a shirt garter that does not require coupling to the wearer's socks and/or feet, is easily adjusted/removed, and is not visible under lightweight fabrics.
SUMMARY
Presented are systems and methods for coupling a garter to shirt-type garment. An aspect of the present disclosure is directed to a garter. The garter may include at least three elongate members, including a first, second and third elongate member. A first end of each of the first and second elongate members may be coupled to a first end of the third elongate member to form a Y-shape. The garter may also include a fastener coupled to a second end of each of the first, second and third elongate members. The fasteners may be configured to be coupled to a garment.
Another aspect of the present disclosure is directed to a garment and garter for keeping the garment in place when worn by a user. The garter may include at least three elongate members, including a first, second and third elongate member. A first end of each of the first and second elongate members may be coupled to a first end of the third elongate member to form a Y-shape. The garter may also include a fastener coupled to a second end of each of the first, second and third elongate members. The fasteners may be coupled to the garment such that the elongate members are configured to extend along a crotch section of the wearer. Additionally, the fasteners may be coupled to the garment such that the fastener of the first and second elongate members are coupled to a front of the garment and the fastener of the third elongate member is coupled to a back of the garment.
A further aspect of the present disclosure is directed to a method of securing a garment in place on a user. The method may include providing a garter having at least three elongate members including a first, second and third elongate member, where a first end of each of the first and second elongate members may be coupled to a first end of the third elongate member to form a Y-shape. The garter may also include a fastener coupled to a second end of each of the first, second and third elongate members. The method may further include coupling the first and second elongate members to a front of the garment and coupling the fastener of the third elongate member to a back of the garment. The fasteners may be coupled to the garment such that the elongate members extend along a crotch section of the user.
The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
The device is explained in even greater detail in the following drawings. The drawings are merely examples to illustrate the structure of preferred devices and certain features that may be used singularly or in combination with other features. The disclosure should not be limited to the examples shown.
FIG. 1 is a front view of an example garter;
FIG. 2A is a front view of an example garter including a releasable fastener;
FIG. 2B is a front view of an example garter including a releasable fastener;
FIG. 3 is a front view of an example garter;
FIG. 4 is a front view of an example garter including a panel;
FIG. 5 is a front view of an example garter;
FIG. 6A is a front view of an example garter and garment;
FIG. 6B is a front view of an example garter and garment;
FIG. 6C is a back perspective view of an example garter and garment; and
FIG. 6D is a back perspective view of an example garter and garment.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “lower,” and “upper” designate direction in the drawings to which reference is made. The words “inner” and “outer” refer to directions toward and away from, respectively, the geometric center of the described feature or device. The words “distal” and “proximal” refer to directions taken in context of the item described and, with regard to the instruments herein described, are based on the perspective of the surgeon using such instruments. The terminology includes the above-listed words, derivatives thereof, and words of similar import.
In addition, various components may be described herein as extending horizontally along a longitudinal direction “L” and lateral direction “A,” and vertically along a transverse direction “T.” Unless otherwise specified herein, the terms “lateral,” “longitudinal,” and “transverse” are used to describe the orthogonal directional components of various items. It should be appreciated that while the longitudinal and lateral directions are illustrated as extending along a horizontal plane, and that the transverse direction is illustrated as extending along a vertical plane, the planes that encompass the various directions may differ during use. Accordingly, the directional terms “vertical” and “horizontal” are used to describe the components merely for the purposes of clarity and illustration and are not meant to be limiting.
Certain examples of the disclosure will now be described with reference to the drawings. In general, such embodiments relate to a garter 100 configured to be coupled to a garment 500 . The garter 100 can include elongated members 200 coupled to fasteners 300 for attaching the garter 100 to the garment 500 . The garment 500 can include, for example, shirts, camisoles, undergarments, undershirts, compression garments, shapewear, tanks, and active wear, and/or any other shirt-type garment worn on the upper body of the wearer.
FIG. 1 provides a front view of an example garter 100 . The garter 100 can include a plurality of elongated members 200 . It is also contemplated that the garter 100 can include a single elongate member 200 and/or any number of elongate members 200 . For example, the garter 100 can include at least three elongate members 200 including a first elongate member 210 , a second elongate member 220 , and a third elongate member 230 . The elongate members 200 can be joined together and/or integrally formed. For example, the elongate members 200 can be joined at a seam, a clasp, a clip (e.g., loop-and-button, toothed, etc.), a snap, a hook and eye, a zipper, a buckle, a toggle, a button, a lace, an adhesive (e.g., VELCRO, fusible interfacing), or any other fastener known in the art. As illustrated in FIG. 1 , the first, second, and third elongate members 210 , 220 , 230 can be coupled at a seam to form a Y-shape. For example, a first end 211 of the first elongate member 210 and a first end 221 of the second elongate member 220 can be coupled to a first end 231 of the third elongate member 230 .
The elongate member 200 can have a length (l) measured between the first end and the second end of the elongate member 200 . It is contemplated that each of the first, second and third elongate members 210 , 220 , 230 can have the same, different, and/or varying length. For example, as provided in FIG. 1 , the first and second elongate members 210 , 220 can have an equal length. For example, the first and second elongate members 210 , 220 can have a length (l) between 5 inches and 10 inches. In another example, the first and second elongate members 210 , 220 can have a length (l) between 7 inches and 8 inches. In yet another example, the first and second elongate members 210 , 220 can have a length (l) between 7½ inches and 8 inches. In a further example, the third elongate member 230 can have a length (l) between 3 inches and 6 inches. In yet another example, the third elongate member 230 can have a length (l) between 4 inches and 5 inches. In another example, the third elongate member 230 can have a length (l) between 4 inches and 4½ inches. In another example garter 100 (not shown), the length of the first, second and/or third elongate members 210 , 220 , 230 is adjustable. For example, the elongate member 200 can include a buckle and a length of material that can be manipulated by the wearer to adjust (lengthen and/or shorten) the length of the elongate member 200 . The elongate members 200 can have a width (w) measured between opposing left and right sides of the elongate members 200 . It is contemplated that each of the first, second and third elongate members 210 , 220 , 230 can have the same, different, and/or varying width (w). For example, as provided in FIG. 1 , the first, second and third elongate members 210 , 220 , 230 can have an equal width (w). For example the first, second and third elongate members 210 , 220 , 230 can have a width (w) between ¼ inch and 1½ inches. In another example, the first, second and third elongate members 210 , 220 , 230 can have a width (w) between ½ inch and 1 inch. In yet another example, the first, second and third elongate members 210 , 220 , 230 can have a width (w) between ½ inch and ¾ inch. As illustrated in FIG. 1 , the first, second, and third elongate members 210 , 220 , 230 can be coupled to form a Y-shape. The spacing between the first and second elongate members 210 , 220 can define an angle (α) measured between the centerline of the first elongate member 210 and the centerline of the second elongate member 220 . In an example garter 100 , the angle (α) can be between 10° and 60°. In another example, the angle (α) can be between 20° and 45°. In a further example, the angle (α) can be between 25° and 45°.
The elongate members 200 can be constructed from a woven or knit fabric. For example, the elongate member can be constructed from a fabric comprising spandex, spandex filament yarn, stretch vinyl, polyester, silk, cotton, rayon, nylon, and/or any other fabric known in the art, including mixtures thereof. For example, the elongate members 200 can be constructed from a fabric comprising an elastomer. An elastomer is a viscoelastic polymer that often has a high failure strain and low elastic modulus, when compared with other materials. In an example garter 100 , the elongate members 200 can be constructed from a woven and/or knit elastomer-containing fabric. For example, the fabric can comprise 1% to 25% (e.g., 15% to 20%), by weight, of elastomer and 75% to 99%, by weight, of non-elastomer. The elastomer-containing fabric can comprise, for instance 1% to 25% spandex (e.g., 10% to 20%, 15% to 20%). In one example, the elastomer-containing fabric is a knitted lace. In another example, the elastomer-containing fabric is knit fabric comprising 16% spandex and 84% nylon. The composition of the fabric can be selected to help provide the desired stretch and strength when using the garter 100 to secure the position of the garment 500 with respect to the wearer's body.
The elongate members 200 can include a fastener 300 for coupling the elongate member 200 to a garment 500 . The fastener 300 can include a clasp, a clip (e.g., loop-and-button, toothed, etc.), a snap, a hook and eye, a zipper, a buckle a toggle, a button, a lace, an adhesive (e.g., VELCRO), or any other removable fastener known in the art. As illustrated in FIG. 1 , the example fastener 300 can include a loop-and-button style garter clip.
Each of the elongate members 200 can include a fastener 300 configured to couple the garter 100 to a garment 500 . For example, the first elongate member 210 can have a fastener 300 coupled to its second end 212 , the second elongate member 220 can have a fastener 300 coupled to its second end 222 , and the third elongate member 230 can have a fastener 300 coupled to its second end 232 . The fastener 300 can be removable and/or permanently coupled to the elongate member 200 .
The fastener 300 can have length (l) measured from the proximal and distal ends of the fastener 300 . For example, the fastener 300 can have a length (l) between ¼ inch and 2 inches. In another example, the fastener 300 can have a length (l) between 1 inch and 2 inches. In a further example, the fastener 300 can have a length (l) between 1½ inches and 2 inches. Accordingly, the garter 100 can have an overall length (L) measured between the distal end of the fasteners 300 coupled to the first and second elongate members 210 , 220 and the fastener 300 coupled to the third elongate member 230 is between 10 inches and 15 inches. In another example, the overall length (L) of the garter 100 is between 12 inches and 14 inches. Likewise, the garter 100 can have an overall width (W) measured between the fastener 300 coupled to the first elongate member 210 and the fastener 300 coupled to the second elongate member 220 between 5 inches and 10 inches. In another example, garter 100 can have an overall width (W) between 6 inches and 8 inches
In another example, the garter 100 can include a releasable fastener 310 . For example, as illustrated in FIGS. 2A and 2B , the garter 100 can include a releasable fastener 310 located on the third elongated member 230 . Though illustrated on the third elongated member 230 , it is contemplated that any of the first, second and/or third elongated members 210 , 220 , 230 can include a releasable fastener 310 . Using the releasable fastener 310 , a wearer of the garter 100 can easily and quickly separate the garter 100 . For example, when needing to adjust the position of the garment 500 , the wearer may not wish to uncouple the fasteners 300 from the garment 500 . The releasable fastener 310 permits the wearer to separate the garter 100 into two distinct pieces such that repositioning and/or removal of the garment 500 is possible without separating the garter 100 fasteners 300 from the garment 500 . Likewise, the releasable fastener 310 permits the wearer to separate the garter 100 into two distinct pieces such that repositioning of the garter 100 and/or access to the area between and the wearer's body is possible without separating the garter 100 /fasteners 300 from the garment 500 . For example, as provided in FIGS. 2A and 2B , the releasable fastener 310 can be located intermediate the first and second end 231 , 232 of the third elongate member 230 . FIG. 2B illustrates the releasable fastener 310 disconnected such that the third elongated member separable into at least two portions (e.g., a first and second portion 234 , 235 ). FIG. 2A illustrates a releasable fastener 310 connected such that the first and second portions 234 , 235 are coupled and the third elongated member 230 forms a single member. The releasable fastener 310 can include any fastener-type known in the art for coupling and uncoupling material. Example releasable fasteners 310 can include a clasp, a clip (e.g., loop-and-button, toothed, etc.), a snap, a hook and eye, a zipper, a buckle, a toggle, a button, a lace, an releasable adhesive (e.g., VELCRO), or any other releasable fastener 310 known in the art. As illustrated in FIGS. 2A and 2B , the releasable fastener 310 can include a snap for connecting the first and second portions 234 , 235 of the third elongated member 230 . A stabilizer and/or interfacing can be used proximate the releasable fastener 310 to provide permanent and/or temporary support and strength to the material of the elongate member near the releasable fastener 310 . Example woven and non-woven stabilizers can include cut-away, tear-away, heat-away, water-soluble, filmoplast, and/or combinations thereof.
In another example, the garter 100 can include a fourth elongate member 240 . For example, as illustrated in FIG. 3 , the garter 100 can include at least four elongate members 200 including a first elongate member 210 , a second elongate member 220 , a third elongate member 230 and a fourth elongate member 240 . As outlined above, the elongate members 200 can be joined together and/or integrally formed. As illustrated in FIG. 3 , the first, second, third and fourth elongate members 210 , 220 , 230 , 240 can be coupled at a seam to form an X-shape. For example, a first end 211 of the first elongate member 210 and a first end 221 of the second elongate member 220 can be coupled to a first end 231 of the third elongate member 230 and a first end 241 of the fourth elongate member 240 .
The fourth elongate member 240 can have a length (l) measured between the first end 241 and the second end 242 of the fourth elongate member 240 . It is contemplated that each of the first, second, third and fourth elongate members 210 , 220 , 230 , 240 can have the same, different, and/or varying length. For example, as provided in FIG. 4 , the third and fourth elongate members 230 , 240 can have an equal length. For example, the third and fourth elongate members 230 , 240 can have a length (l) between 3 inches and 6 inches. In another example, the third and fourth elongate members 230 , 240 can have a length (l) between 4 inches and 5 inches. In a further example, the third and fourth elongate members 230 , 240 can have a length (l) between 4 inches and 4½ inches. outlined above, it is also contemplated that the length of the first, second, third and/or fourth elongate members 210 , 220 , 230 , 240 are adjustable. The fourth elongate member 240 can have a width (w) measured between opposing left and right sides of the elongate member. It is contemplated that each of the first, second, third and fourth elongate members 210 , 220 , 230 , 240 can have the same, different, and/or varying width (w). For example, as provided in FIG. 4 , the first, second, third and fourth elongate members 210 , 220 , 230 , 240 can have an equal width (w). For example the first, second, third and fourth elongate members 210 , 220 , 230 , 240 can have a width (w) between ¼ inch and 1½ inches. In another example, the first, second, third and fourth elongate members 210 , 220 , 230 , 240 can have a width (w) between ½ inch and 1 inch. In yet another example, the first, second, third and fourth elongate members 210 , 220 , 230 , 240 can have a width (w) between ½ inch and ¾ inch. As illustrated in FIG. 3 , the first, second, third and fourth elongate members 210 , 220 , 230 , 240 can be coupled to form an X-shape. The spacing between the first and second elongate members 210 , 220 and the third and fourth elongate members 230 , 240 can define an angle (α) measured between the centerline of each of the respective elongate members 200 . It is contemplated the angle (α) between the first and second elongate members 210 , 220 can be the same and/or different from the angle (α) between the third and fourth elongate members 230 , 240 . As illustrated in FIG. 3 , the angle (α) between the first and second elongate members 210 , 220 is equal to the angle (α) between the third and fourth elongate members 230 , 240 . In an example garter 100 , the angle (α) between the third and fourth elongate members 230 , 240 can be between 10° and 60°. In another example, the angle (α) between the third and fourth elongate members 230 , 240 can be between 20° and 45°. In a further example, the angle (α) between the third and fourth elongate members 230 , 240 can be between 25° and 45°. The fourth elongate member 240 can also include a fastener 300 configured to couple the fourth elongate member 240 to a portion of a garment 500 . For example, the fourth elongate member 240 can include a fastener 300 removably and/or permanently coupled to its second end 242 .
In another example, the garter 100 can include a panel 400 located intermediate the proximal (front) and distal (back) portions of the garter 100 , as illustrated in FIG. 4 . For example, the garter 100 can include a material panel 400 that can be located proximate the crotch section of the wearer then the garter 100 is worn with a garment 500 . The panel 400 can be coupled to each of the elongate members 200 . For example, the first end of each of the first, second and third elongate members 210 , 220 , 230 can be coupled to the panel 400 . Likewise, the panel 400 can be coupled along a length of each of the first, second and third elongate members 210 , 220 , 230 . The panel 400 can define a triangle shape, a rhomboid shape, a rectangular shape, square shape or any other regular or irregular shape known in the art. The panel 400 can be constructed from the same and/or different material as the elongate members 200 .
In further example, the garter 100 can include two separate elongate members 200 . For example, as illustrated in FIG. 5 , the garter 100 can include a first elongate member 210 and a separate, second elongate member 220 . The first end 211 of the first elongate member 210 and the first end 221 of the second elongate member 220 can be coupled to fasteners 300 for joining the garter 100 to the front of a garment 500 . Likewise, the second end 212 of the first elongate member 210 and the second end 222 of the second elongate member 220 can be coupled to fasteners 300 for joining the garter 100 to the back of a garment 500 . It is contemplated that the first elongate member 210 will be used in conjunction with the second elongate member 220 . In another example, the first elongate member 210 and/or second elongate member 220 can be used individually. For example, only the first elongate member 210 is coupled to the garment 500 .
The first and second elongate members 210 , 220 can have a length (l) measured between the first end 211 and a second end 212 of the first elongate member 210 , and between the first end 221 and second end 222 of the second elongate member 220 . It is contemplated that the first elongate member 210 and the second elongate member 220 can have the same, different, and/or varying length. For example, as provided in FIG. 5 , the first and second elongate members 210 , 220 can have an equal length. In one example the first and second elongate members 210 , 220 can have a length (l) between 5 inches and 10 inches. In another example, the first and second elongate members 210 , 220 can have a length (l) between 6 inches and 8 inches. In a further example, the first and second elongate members 210 , 220 can have a length (l) between 6½ inches and 7½ inches. In yet another example, the first and second elongate members 210 , 220 can have a length (l) of 7 inches.
As outlined above, it is also contemplated that the length (l) of the first and second elongate members 210 , 220 are adjustable. The first and/or second elongate members 210 , 220 can have a width (w) measured between opposing left and right sides of the elongate member. It is contemplated that each of the first and second elongate members 210 , 220 can have the same, different, and/or varying width (w). For example, as provided in FIG. 5 , the first and second elongate members 210 , 220 can have an equal width (w). For example the first and second elongate members 210 , 220 can have a width (w) between ¼ inch and 1½ inches. In another example, the first and second elongate members 210 , 220 can have a width (w) between ½ inch and 1 inch. In yet another example, the first and second elongate members 210 , 220 can have a width (w) between ½ inch and ¾ inch.
As outlined above, the fasteners 300 can be used to couple the garter 100 to a garment 500 . FIGS. 6A-6D illustrate a garter 100 coupled to a garment 500 as worn by as user. As provided in FIGS. 6A-6D , the garter 100 can be coupled to the garment 500 such that the garter 100 extends around the crotch region of the wearer. For example, the fasteners 300 of the first and second elongate members 210 , 220 can be coupled to the front of the garment 500 . Likewise, the fastener 300 of the third elongate member 230 can be coupled to the back of the garment 500 . Where the garter 100 includes a fourth elongate member 240 , as illustrated in FIG. 3 , the fourth elongate member 240 can also be coupled to the back of the garment 500 .
The garter 100 can be used to maintain the position of the garment 500 . For example, FIGS. 6A and 6B provide a front view of an example garter 100 when worn with a garment 500 . As illustrated in FIG. 6B , as the position of the garment 500 changes (e.g., rides up the wearer's torso), the garter 100 secures at least a portion of the front hem at a desired position (e.g., proximate the wearer's waist). FIGS. 6C and 6D provide a back view of an example garter 100 when worn with a garment 500 . As illustrated in FIG. 6D , as the position of the garment 500 changes (e.g., rides up the wearer's torso), the garter 100 secures at least a portion of the rear hem at a desired position.
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. | This disclosure relates generally to a shirt garter (also known as a shirt stay). More specifically, this disclosure relates a shirt garter that extends around the crotch region of the wearer and is designed for use with a camisole or other shirt-type garment. | 0 |
RELATED APPLICATIONS
[0001] This application is related to U.S. Pat. No. 5,892,566 and U.S. Pat. No. 6,079,829 by the instant inventor. The disclosures of these patents are incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention is directed to eye tracking devices, particularly, to an eye tracking device suited for analyzing eye-movement of a patient undergoing diagnostic treatment within a magnetic resonance imaging (MRI) apparatus wherein such eye tracking device utilizes an out-of-band light source, and most particularly, wherein such diagnostic treatment may involve visual stimulation.
BACKGROUND OF THE INVENTION
[0003] Monitoring of eye motion can provide a variety of information. Sleep researchers, for example, use eye motion as an indicator of various sleep stages. Also, persons with limited muscle control can use eye motion to interact with others or to control specialized equipment. Military applications that follow eye motion for targeting purposes or vehicle control have also been developed. Eye tracking devices are even used in the video game entertainment industry, where interactive environments adjust to follow the motion of a player's eye.
[0004] Another important use of eye tracking is for a patient undergoing diagnostic treatment within a MRI apparatus, where it may be necessary to know the behavior of the patient's eyes during the diagnostic procedure, particularly if the patient is viewing visual stimulii.
[0005] Many eye tracking devices monitor muscle activity to assess eye motion. For example, U.S. Pat. No. 5,517,021 discloses an eye tracking apparatus that detects bio-electromagnetic signals generated by the muscles that move an individual's eye. The signals are analyzed and corresponding control signals are produced as output. U.S. Pat. No. 5,422,689 discloses an eye tracking device that uses sensors to monitor electro-oculogram signals produced by eye motion. The sensors are coupled with a microprocessor that analyzes the signals to determine an operator's horizontal or vertical eye movement.
[0006] Other eye tracking devices rely on changes in light patterns to track eye motion. For example, U.S. Pat. No. 5,270,748 discloses an eye tracker that uses detection devices for determining the point of regard of an operator. Included conversion circuitry determines the position of fovea-reflected light, allowing computation of an individual's visual axis and the associated point of regard. U.S. Pat. No. 5,345,281 discloses a system that uses reflected infrared light to track the gaze of an operator's eye. The U.S. Pat. No. 5,345,281 system directs infrared light towards the eye and considers differences in infrared reflectivities between the pupil, iris, and sclera to compute eye position. U.S. Pat. No. 5,583,335 discloses an eye tracking system that includes an active matrix display. Pixels in the display are aligned with corresponding photodetectors. Axial light rays from the display pixels are reflected by the eye and detected by respective photodetectors. In turn, the array of photodetectors generates an eye-position-indicating electrical signal.
[0007] Although known detectors provide certain information about eye motion, they have limitations. In many cases, simple eye motion monitoring does not provide a complete picture. For example, eye tracking devices that monitor eye-moving muscles typically do not sense pupil action. Feedback regarding pupil contraction and dilation provides important cues during diagnostic medical procedures. Devices that do not track this pupil activity do not provide enough information for many types of medical tests. Other trackers, such as those that monitor reflected light, may provide some information about pupil action, but do not provide real-time visual images of the eye, itself. Without this visual image to provide context, electrical eye-position information may be hard to interpret and almost impossible to cross reference.
[0008] U.S. Pat. No. 5,892,566 teaches video tracking of the eye as embedded in a visual presentation system which relies on either ambient light or light from the visual system to illuminate the eye. The problem with this system is that signals from the visual presentation system may be temporarily intermittent or be of such a limited bandwidth as to make illumination of the eye unreliable for the purpose of forming an image of the eye or its structures. Similar problems stem from reliance on ambient light for illumination. While ambient light is usable for illumination, it is desirable to use a dedicated light source, either visible or non-visible (NV), to illuminate the eye.
[0009] As taught in U.S. Pat. No. 6,079,829, better results are obtainable when the source of illumination has a wavelength that is different than that used for the visual presentation/stimulus, thereby rendering the illumination independent of the visual signal. Infra-red, ultraviolet, or an equivalent NV portion of the light spectrum has been found to be a preferred source of dedicated illumination.
[0010] The physical and operational nature of known eye-tracking devices makes them unsuitable for use in many testing environments. For example, MRI diagnosis equipment creates an environment which makes it impossible to use known eye-tracking devices therein.
[0011] In operation, a typical MRI apparatus relies upon hydrogen protons which have a dipole movement and therefore behave as would a magnetic compass. In MRI scanning, the MRI apparatus operates as a large magnet wherein the protons align with the strong magnetic field but are easily disturbed by a brief radio frequency (RF) pulse of very low energy so as to alter their alignment. As the protons return to their orientation with the magnetic field, they release energy of a radio frequency that is strongly influenced by the biochemical environment. The released energy as detected and mathematically analyzed for display as a two dimensional proton density image according to the signal intensity of each issue.
[0012] The magnetic coils of the MRI apparatus are permanently fixed within a large structure so as to form a large magnet with a very confining entrance known as the bore. A patient is placed upon a scanner table that is integrated with the MRI apparatus and slid into the middle of the bore.
[0013] Eye tracking devices used during MRI scanning must transmit signals in a format that is not affected by the MRI apparatus. The magnetic and RF used by the MRI apparatus typically disrupt signals. Also, eye tracking devices used during MRI must not interfere with the MR imaging process, whether due to material construction or method of signal transmission. For these reasons, most conventional eye tracking devices are not suited for use in this environment.
[0014] Eye tracking devices used during MRI scanning must not interfere with the motion of an individual within the bore. Since the bore is a low-clearance area, eye tracking equipment used therein must be streamlined: bulky items simply will not fit.
[0015] Additionally, the eye tracking equipment used in MRI must not interfere with the operation of visual stimulation or patient comfort systems used as part of the diagnostic procedure.
[0016] U.S. Pat. No. 5,414,459 entitled Fiber Optic Video Glasses and Projection System addressed the need for eye stimulation within an MRI apparatus. The '459 device is formed from a shape and material of construction that are suitable for use within an MRI environment without the need for additional shielding. U.S. Pat. No. 5,892,566 teaches the integration of an eye imaging system into the system disclosed in U.S. Pat. No. 5,414,459, while U.S. Pat. No. 6,079,829 teaches the use of out-of-band illumination in the '566 device.
[0017] A limitation of the systems disclosed in these patents is that the teachings provide solutions for MR inert visual stimulation and eye tracking only for fiber optic glasses based visual presentation systems.
[0018] There is another class of visual presentation devices used for MRI that is based on the use of a projector and screen, such as taught in U.S. Pat. No. 6,774,929. These types of devices differ fundamentally from the fiber optic glasses in that the image viewed by the patient is created by direct transmission from a projector onto a screen, as opposed to the projector image being linked to an image plane by a fiber optic image guide, as in the fiber optic glasses systems. Projection based visual systems offer some distinct advantages over fiber optic glasses systems, such as ease of use and lower cost.
[0019] Eye tracking for projector based systems is also of interest for data validation and diagnostic information. Current eye tracking techniques for MR projection systems are based on the use of cameras and IR sources located outside of the magnet bore.
[0020] However, the devices of the prior art all require a very precise protocol of acquiring, aligning and focusing of the illumination beam, the camera angle and the viewable object. If any of these components is out of alignment, the tracking will not be usable. Further, because these are all separate elements any of them can be dislodged by movement of the patient or contact with the MRI.
[0021] Thus, what is needed is an eye tracking device that includes advantages of the known devices, while addressing the shortcomings they exhibit.
SUMMARY OF THE INVENTION
[0022] Accordingly; it is an objective of this invention to provide an eye tracking device usable with projection type visual systems. The device should eliminate the alignment and focusing requirements of separate components. The eye tracking device should be impervious to magnetic environments and the output of MRI equipment. The device should not only indicate eye motion, but should also monitor pupil state. The device should be compact enough to monitor a patient located within the bore of MRI equipment and provide diagnostic feedback that allows comparison of eye movement and brain activity. Additionally, the device should be compatible with patient relaxation equipment used during an MRI session. The device should include a dedicated light source to illuminate the eye which has a wavelength that is different than that used for the visual presentation/stimulus, such as infrared illumination or the like, thereby rendering the illumination independent of the visual signal.
[0023] Another objective of the instant invention is an eye-tracking system that analyzes the motion of an individual's eye(S). As will be seen, the system is especially well-suited for analyzing the eye movement of a patient undergoing diagnostic treatment within a magnetic resonance imaging apparatus, and during which the patient is provided visual information by a video projection system.
[0024] A further objective of this invention provides a fiber optic image guide which forms an image of a patient's eye by utilizing the light delivered by a fiber optic illumination source. The illumination may utilize a wavelength which is out-of-band from that used for the visual presentation or stimulus, e.g. IR or an equivalent NV portion of the light spectrum. The fiber image guide thus conveys a real-time image of an patient's eye(s) to an included image conversion device. The conversion device, in turn, generates a electrical representation of the real-time eye image received from the fiber optic image guide. The input end of the image guide and the output end of the fiber optic illumination are integrated with the viewing device used by the patient so that when the patient adjusts the viewing device to view the projection screen, the correct image of the patient's eye(s) is automatically formed, without further adjustment of either the image guide or the illumination source.
[0025] A further objective of the invention is that because the eye imaging system moves with the patient, the patient's eye(s) can always be imaged regardless of the patient's location regardless of the patient's location within the MRI apparatus. The fiber optic nature of the image guide and the illumination system make them impervious to the magnetic and RF fields associated with the device, as well as insuring the eye tracking system will not interfere with the MRI imaging process.
[0026] The eye-tracking system of this invention locates key reference points in the digitized eye image and compares the location of those points to the position of corresponding reference points located within a control image. This comparison is made by a computer interfaced with the conversion device. The computer is directed by software that analyzes the relative positions of these reference points. Based upon the analysis, the computer software provides diagnostic feedback.
[0027] Thus, it is yet another objective of this invention to provide a viewing device used by the patient to view a projection screen, such device integrating fiber optic illumination, fiber optic imaging, and optical elements to aid in viewing the projection screen.
[0028] It is another objective of the present invention to provide an eye tracking system that is impervious to the highly magnetic and EMI-rich environment of the apparatus.
[0029] It is also an objective of the present invention to provide an eye tracking system that may be combined with diagnostic or relaxation equipment within confined environments.
[0030] It is yet a further objective of the present invention to provide an eye tracking system that selectively provides a visual image of a patient's eye for archival and/or comparison purposes.
[0031] It is also an objective of the present invention to provide an eye tracking system that allows comparison of brain activity with resultant eye motion.
[0032] It is a further objective of the present invention to provide an eye tracking system that allows diagnostic analysis of eye response to visual or other types of stimulation.
[0033] It is yet another objective of the present invention to provide an eye tracking system that provides diagnostic information related not only to eye motion, but to pupil state, as well.
[0034] It is yet an additional objective of the present invention to provide an eye tracking system that provides an improved image of the eye and its structures by including a source of illumination which is independent of the visual signal to provide reliable and repeatable illumination conditions.
[0035] Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWING
[0036] FIG. 1 is an exploded pictorial view of the eye tracking system of the present invention;
[0037] FIG. 2 is a pictorial representation of the viewing device used by a patient; and
[0038] FIG. 3 is an pictorial view of the device showing coaxial eye imaging and eye illumination.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0039] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification.
[0040] Now with respect to FIG. 1 , the fiber optic eye tracking system 1 of the present invention is shown. The present eye tracking system 1 includes five cooperative subsystems: a visual stimulation subsystem 10 , an illumination subsystem 30 , a viewing subsystem 20 , an image conveyor subsystem 40 and an image processing subsystem 50 .
[0041] The visual stimulation subsystem, the illumination subsystem, the imaging receiving subsystem and the viewing subsystem are made from non-magnetic materials and are inert to the electromagnetic forces produced during MRI imaging. Additionally, the subsystems do not produce any interference with the imaging process. These subsystems may be used inside the bore of an MRI apparatus or unshielded within the MRI environment.
[0042] In this embodiment, the visual stimulation subsystem 10 includes a video output device 12 interfaced with a rear projection screen 14 and the viewing subsystem 20 . This allows a visual stimulation picture to be projected on the screen 14 with the patient's view optically redirected by mirror 24 in viewing subsystem 20 to focus on the screen.
[0043] The viewing subsystem 20 integrates the mirror 24 with the output end 34 of the illumination fiber guide 32 and the input end 43 of the conveyor image guide 42 . The mirror 24 is of such material or mechanical construction that allows the out-band illumination from fiber end 34 to pass through the mirror without interfering with the viewing of the visible light image, as well as allowing an uncompromised view of the patient's eye(s) by the image guide end 43 . The advantage of this system is that eye imaging is independent of the patient's optically redirected view or motion of the patient's head, with the additional advantage of providing immediate eye tracking information as soon as the mirror 24 has been positioned, either by the patient or external direction, for viewing of the projection screen 14 .
[0044] As shown in FIG. 2 , the viewing subsystem 20 contains the viewing mirror 24 , the end of the illumination guide 34 , and the end of the image guide 43 . The viewing subsystem may or may not have an optical lens for viewing the screen 14 and the viewing subsystem may or may not be supported by the patient. For example, a monocular viewing device or a binocular device could be attached directly over the patient's eye(s) by tape, headband, ear piece, nose clamp or other suppport. Alternatively, the viewing device could be moveably mounted within the MRI apparatus in close proximity to the patient's eyes.
[0045] The illumination subsystem 30 includes a flexible fiber optic guide 32 having a first end 33 in optical communication with the second end 34 . The first end and the second end are spaced apart by a guide middle portion 35 . The first end 33 is optically coupled at 37 to an out-of-band light source 38 which is coupled to a power source for generation of light therefrom. The second end of the guide may utilize an optical element 36 to properly distribute the illumination. The second end 34 is integrated with mirror 24 such that the NV output of the guide is directed toward a selected region of the eye, even as the viewing mirror 24 is adjusted or the patient moves his head.
[0046] Depending on the type of eye tracking used, the fiber optic illumination guide 32 or the light output from that guide may be coaxial with the image conveyor guide 42 or the image input to that guide, as shown in FIG. 3 .
[0047] The image conveyor subsystem 40 delivers an electrical representation of the optically transferred real time image of the patient's eye to the image processing subsystem 50 . A copy of the original and digitized images may be stored for later use as a control image. The image processing subsystem analyzes the electrical representation and generates relevant feedback.
[0048] The image conveyor subsystem 40 includes a flexible fiber optic image guide 42 having a first end 43 in optical communication with a second end 44 . The first end 43 and second end 44 are spaced apart by an image guide middle portion 45 . The first end 43 is directed at the patient's eye 18 during a MRI session. The first end 43 is adjustably attached to the image viewer frame and optically coupled to the patient's eye(s) such that as the mirror 24 is adjusted or if the patient moves his head, the patient's eye motion will still be tracked accurately.
[0049] The image conveyor subsystem includes a video camera 48 interfaced with the fiber optic image guide second end 44 . Because the fiber optic image guide first and second ends, 43 and 44 , are in optical communication, the fiber optic image guide acts as a flexible lens extension for the video camera 48 . As a result, the fiber optic image guide 4 conveys a real-time eye image to the video camera 48 . The video camera 48 creates an electrical representation of the transmitted real-time image and forwards the resulting electrical representation to the image processing subsystem 50 .
[0050] The image processing subsystem 50 includes a computer 52 interfaced with the video camera 48 . The computer 52 receives electrical output from the video camera 48 and performs operations directed by included computer hardware and software. More specifically, the video camera 48 forwards an electronic representation of the eye image to the computer 52 , where the included hardware/software directs the computer to process the electronic eye image. In one embodiment, the software analyzes the digitized image of the eye and compares the location of a first reference point therein, with the location of a corresponding second reference point located in a control image. The control image may be a previously-stored image of the patient's eye E or some other suitable image. After comparing and tracking the location of corresponding reference points, the software produces diagnostic feedback. This feedback includes graphs, stimulus time/eye position charts, and a visual display of the current and/or control images of the eye E. The feedback allows a technician to make patient assessments. The feedback can also be used to control and adjust the viewing mirror 24 and optics 26 .
[0051] Although the invention has been described in terms of a specific embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements and substitutions can be made without departing from the spirit of the invention. The scope of the invention is defined by the claims appended hereto. | An eye imaging system having an image viewing subsystem for interfacing with an MRI patient. The imagine viewing subsystem incorporates fiber-optic illumination and imaging subsystems that enable automatic eye imaging for eye tracking. The eye imaging system analyzes motion of an patient's eye in response to visual stimuli and includes an image conveyor subsystem, an image receiving subsystem, and an image processing subsystem. The light source utilized to form the reflected images is an independent source of illumination. | 0 |
This is a division of application Ser. No. 348,814, filed Apr. 6, 1973, now U.S. Pat. No. 3,856,974.
BACKGROUND OF THE INVENTION
The present invention relates to an improvement in the production of continuous metal filaments of indefinite length which are normally wound on spools. More specifically, for the purposes of the invention, filament is herein used to represent a slender body whose transverse dimensions are much less than its length. In the present context, the filaments may be ribbons, sheets, wires or irregular cross-sections.
During recent years, researchers developed various methods directed to the formation of metal filaments which avoid the inherent difficulties of previous casting and rolling techniques. These methods include, for example, melt extraction and chill block spinning.
Melt extraction connotes a process wherein a cold quenching wheel rotates at high velocity in "kissing", i.e. skimming, contact with a liquid metal surface. The molten metal wetting the wheel is carried up out of the molten bath, where it solidifies and thereby shrinks away from the wheel and is flung off by centrifugal action. The melt extraction techniques discussed herein are to be distinguished from other extraction methods such as those described in U.S. Pat. No. 1,025,848 to Wagner and U.S. Pat. No. 2,074,812 to Sendzimer, which primarily employ a casting technique in which the cold wheel is substantially immersed in the liquid metal and in which the rotational velocity of the wheel is appreciably lower than in the melt extraction.
Chill block spinning is exemplified by U.S. Pat. No. 905,758 to Strange and Pim, U.S. Pat. No. 2,825,108 to Pond, U.S. Pat. No. 2,886,866 to Wade, and U.S. Pat. No. 2,899,728 to Gibbons. In this process, a free jet of molten material is impinged upon a moving chilled quenching surface, preferably a rotating wheel. The molten jet is solidified in the form of a ribbon or sheet and is flung away from the rotating chill surface by centrifugal action.
One important disadvantage in the melt extraction and chill block spinning processes as presently employed is that they produce long, but not genuinely continuous filaments. The flinging action which removes the filament from the wheel induces an oscillating or whipping motion in the filament which inevitably causes breakage. Presently filaments are produced with a maximum length of only about 300 meters. Continuous metal filaments in the range of 1,000 to greater than 30,000 meters in length are required for such applications as strapping, springs, filament-wound vessels, aerospace skins and the like.
An additional problem encountered in the melt extraction and chill block spinning process is that of winding the lengths of filament formed. The incorporation of a tension regulated winder or similar collecting device into the system results in a great amount of stress being transmitted back to the solidification zone, a factor which contributes to the breakage of the filaments. Since the "down time" caused by rethreading the filaments onto the winder after breakage is considerable, the metal filaments must be wound in a separate operation. There is obviously a need for a method to produce continuous lengths of metal filaments which can be wound concomitantly with production.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to produce continuous metal filament, or ribbon or sheet.
It is another object to produce a continuous filament or sheet which can be automatically collected in a neat coiled package concomitantly with its production.
These and other objects and advantages will become apparent from the description and examples provided herein.
Accordingly, this invention is directed to an improvement in the production of metal filaments, ribbons or sheets. In the production of these materials using a rotating wheel as the quenching source, the improvement comprises establishing a tension-free zone by positioning a pressure exerting means in nipping contact with the quenching source beyond the point of solidification; ideally, just at the point where shrinkage of the filament causes detachment from the quenching source. In an additional aspect of the invention, the filament can then be directed from the nipping means and wound on a tension controlled winder or other collecting means such as a spinning bucket. Thus, the nipping action isolates the fragile filament or sheet in the solidification zone from the tension exerted by the winder. The continuous tension exerted by the winder and/or tension regulating mechanism used in conjunction with the winder prevents whipping, thereby avoiding filament breakage and enabling production of a truly continuous filament.
The nipping means employed may be any device having freedom of movement and capable of exerting sufficient pressure on the solidifying filament to counteract the stress transmitted by the winder and also by inherent centrifugal and gravitational forces thereby preventing breakage. The device may be in the form of a bar, a blunt blade or preferably, a cold wheel freely rotating or driven at the same surface velocity as the quench wheel. In this regard, it is to be noted that the role of the nipping device is not merely that of a "guide". It is intrinsic to this invention that pressure be exerted by the device onto the solidifying filament and not merely that the filament be guided around the device. The mere positioning of a guide wheel at the point of solidification does not prevent breakage of the filament since it does not counteract the centrifugal or gravitational forces or the tensional stress transmitted by the winder. The arrangement of the invention requires, as an essential facet, freedom of movement so that the nipping device can readily adapt to use in forming filaments of various thickness and does not have to be individually adjusted.
The amount of pressure which the device exerts upon the filament depends upon the magnitude of the winding tension and the coefficients of friction between the filament and the quench roller and between the filament and nip roller. The relationship between those quantities is expressed by the following inequality: ##EQU1## wherein P is the applied nipping pressure represented in lbs/inch of filament width. T is the winding tension in lbs/inch of filament width. μQR and μNR are the coefficients of friction between the filament and the quench roller and the filament and the nip roller respectively.
This novel method for producing continuous wound filaments could be easily adapted to any process for preparing filaments in which the quenching step is carried out on a chill wheel, drum, etc. and the filament is separated after solidification by centrifugal force.
This method is particularly useful in very high speed forming operations where formation and subsequent winding occurs very rapidly and a great amount of stress is transmitted to the solidifying filament.
While this application is directed to the use of the nipping pressure means in conjunction with the use of a tension regulating winder, it is obvious that the invention also includes the production of long or continuous filaments which are not wound concomitantly with their production but are collected in another manner.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates diagrammatically an apparatus which uses a wheel melt extraction in conjunction with a nipping wheel in accordance with the invention to produce continuous filaments. FIG. 1a illustrates the relationship of the melt extraction wheel, nip roller and filament during start-up.
FIG. 2 represents a modified apparatus in accordance with the invention in which a molten jet is extruded onto a chill wheel before being acted upon by the nipping roll.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 are representative of the novel aspects of the present invention. In FIG. 1, a cold wheel 10 rotates in "kissing" contact as shown at 12 with surface 17 of a liquid metal 18 confined in a suitable reservoir 11. The molten metal solidifies on the surface 19 of the wheel 10 and is carried up out of the reservoir 11, and at a point 13 at which it begins to shrink away from the wheel 10 it comes into contact with a second cold wheel 14 which exerts a nipping pressure (between wheels 10 and 14) on the filament 15. The filament 15 is then continuously drawn by a conventional tension control device 16 and wound onto a roller 20. The position of the nipping roller 14 and the pressure which it exerts on the filament 15 are controlled by means of a pressure exerting mechanism such as an air cylinder operating through a conventional connecting link between the roller 14 and the cylinder (not shown).
During start-up of the process, the nipping roller 14, as shown in FIG. 1a is swivelled to a remote position. Rotation of the quenching wheel 10 is initiated and the level of liquid metal 18 in the reservoir 11 is raised by opening a valve from a supplemental reservoir (not shown). When the liquid metal 18 contacts the quench wheel 10, at the contact point 12, formation of the metal filament commences. The filament is flung away by centrifugal action at the point 13 and the nipping roller 14 is then converged toward quenching wheel 10 so that the filament 15 is held between these rotating elements and the filament is conveyed via a tension control regulator 16 to a winder.
The pressure exerted by the nipping roller 14 on the filament 15 isolates the fragile solidification zone 12 to 13 from the tension of the winding arrangement and prevents filament breakage from this source and/or from "whipping" of the filament as it is drawn by the winder. The metal filament 15 is then continuously wound up in packages whose lengths are determined only by the capacity of the winder. Molten metal is admitted to the reservoir 11 to maintain the continuous filament forming process.
Moderate changes in the rotational speed of the quench roller 10 or changes in the thickness of the filament do not substantially affect the winding process or continuity of the filament. As noted hereinabove, an air cylinder or other suitable positioning and/or pressure applying device may be used to hold the nip roller against the quench roller thereby permitting the filament thickness to vary without reduction of nipping pressure.
In FIG. 2, an alternate apparatus is employed to provide a similar result. In FIG. 2, the melt 28 is contained in an insulated container 29 provided with heating element 31. During start-up of the process, the nipping roller 24 is swiveled to a remote position in a manner as described in connection with FIG. 1a. Rotation of the quenching wheel 21 is initiated and inert gas 34 is admitted to the melting container or vessel 29. A molten jet 32 is extruded from a suitable opening 33 in the bottom of the container 29 and impinges upon the rotating quench wheel 21 to form a filament 30. The filament has a tendency to be flung away by centrifugal action at that point 23. The nipping roller 24 is converged on wheel 21 and the solidified filament 25 is conveyed to a tension controlled windbar 26 to a storage roller 27 as previously described in connection with FIG. 1.
The nipping rollers 14 and 24 are preferably freely rotating, lightweight devices supported by roller bearings. They may comprise a solid cylinder, a hollow cylinder, or a composite cylinder. A desirable configuration has been found to be a composite hollow cylinder having an outer shell consisting of a material of a high coefficient of friction bonded to an inner annular tube of high strength. The high coefficient of friction of the outer material permits the use of lower nipping pressures as expressed by equation (1). The use of an annular core of high strength permits construction of a nip roller of low movement of inertia. The outer material must also be resistant to the temperatures of the solidified filament at the point of contact.
Included among the materials suitable for use in the outer shell of the nipping wheel used in the practice of the present invention are any materials which are wear resistant under the temperatures of use. Illustrative examples include organic impregnated woven asbestos-brass wire compositions manufactured by Raybestos-Manhattan Corporation and designated as US98 and US2010. The inner core may be steel or similar high strength material.
The wind-up mechanism may be used alone or in conjunction with a separate tension regulating device as 16 and 26. If the wind-up mechanism is used alone, it should contain a means of regulating tension as for example by means of a slip clutch on the winding drum. Alternatively, separate tension regulating devices may be employed; illustrative devices could be counter-balanced, spring-loaded or balanced by means of an air cylinder.
The invention will be further described in the following illustrative examples:
EXAMPLE 1
A grey iron alloy containing 3.4 weight percent carbon, 2.2 weight percent silicon, 0.6 weight percent manganese, 0.2 weight percent phosphorus and 0.01 percent sulfur was melted at 1200°C. in a conventional apparatus for melt extraction similar to that depicted schematically in FIG. 1. However, a nip roller similar to roller 14 was not utilized.
The quenching wheel was constructed of oxygen free high conductivity copper of 8 inch outside diameter and provided with internal channels for the circulation of cooling water. Cooling water was admitted through a rotary union on one side of the hollow quenching wheel shaft and was withdrawn through a rotary union on the opposite side. The face width of the quenching wheel was one inch.
Rotation of the quenching wheel was commenced at 1800 revolutions per minute. The level of the grey iron melt in the crucible was raised by opening a valve to the connecting reservoir. The liquid metal surface was brought into "kissing" contact with the rotating quench wheel. A solidified filament of 1 inch width and 0.0001-0.008 inch thickness was formed on the face of the quench wheel and was flung away by centrifugal action. The arcuate path of the solidified filament commenced at a tangent to the surface of the quenching roll, traveled upward at an angle of 30°-60° to the horizontal, reached a point of maximum elevation and finally turned downward and fell into a catch basin on the floor. The path of the filament was severely affected by "whipping" oscillations induced by random changes in the point and angle of departure of the filament from the quench roll. The filament remained continuous for periods of several seconds until at irregular intervals the oscillations caused the filament to break off near the quench roll.
The filament was seized near the point of departure from the quench roll and guided to engage the winder. At filament tensions of 1-100 grams filament oscillations persisted causing eventual breakage. During the periods between breaks, only relatively unsatisfactorily loosely wound filament was produced. With higher winding tension the filament ruptured in the solidification zone immediately as it was connected to the winder.
EXAMPLE 2
The apparatus of Example 1 was modified by utilizing a nipping roller 14 as depicted in FIG. 1. The nipping roller was of 4 inch overall diameter and consisted of a 4 inch diameter hollow steel cylinder of one-quarter inch wall thickness. In addition, the nip roller was of 2 inch face width and was supported by a one-half inch steel shaft mounted on roller bearings. It was freely rotatable.
The melt extraction process was started with grey iron alloy as described in Example 1. The nip roller 14 was swiveled to the remote position depicted in FIG. 1a, the path of the centrifugally flung filament passed above and between the quench roll and the nip roll. The nip roller was then actuated to the "closed" or converged position by means of an air cylinder which pressed the filament against the quenching wheel with a force of 30 pounds. This pressure was chosen by reference to equation (1) as will be explained below. The filament was seized as it passed through the nip zone and guided to engage the winder. The filament was then continuously wound without interruption at 10 pounds tension. Tight, uniform packages of grey iron ribbon 1 inch wide by 0.008 inch thickness were produced for 8 hours without experiencing a break.
The coefficients of dynamic friction for several metal systems are given by The Handbook of Chemistry and Physics, 51st Edition, pp. F15-F17. The coefficient of friction between grey iron and steel is 0.4. The coefficient of friction between steel and a copper film (8 kg. load) is given as 0.2. Taking the latter to be the same as the friction coefficient between grey iron and copper, the necessary minimum nip roll pressure was obtained from equation (1) by making the following substitutions.
T = 10 lbs/in
μQR = 0.2
μNR = 0.4
from equation (1) ##EQU2##
P ≧ 16.67 lbs/in To provide a margin of safety, the nip roll pressure was set at 30 pounds.
EXAMPLE 3
An alloy formulated to be amorphous upon quenching was charged in an apparatus for chill block spinning similar to that depicted schematically in FIG. 2. However, no nip roller was provided. The quenching wheel was an annular cylinder 16 inch O.D. × 15 inch I.D. × 2 inch face width construction of oxygen free high conductivity copper. Steel end plates and a center supporting shaft were attached to the copper cylinder. The supporting shaft was of 11/2 inch O.D. and 1/2 inch I.D. Its interior communicates with the interior of the quenching wheel. Cooling water was circulated through the steel shaft and the interior of the quenching wheel.
The alloy to be spun consisted of 38 atomic percent iron, 39 atomic percent nickel, 14 atomic percent phosphorus, 6 atomic percent boron and 3 atomic percent aluminum. It was melted in an argon atmosphere at 1000° C. The quench wheel was set into motion at 1800 rpm and the molten alloy extruded through an orifice of 0.010 inch diameter at 300 cm/sec. The molten jet traversed a one inch air gap and impinged upon the surface of the rotating quench wheel. A solidified filament 0.025 inch wide by 0.002 inch thick was formed and was flung away by centrifugal action. The path of the solidifed filament commenced at a tangent to the surface of the quench wheel, traveled downward at an angle of 30°-60° to the horizontal and terminated on the laboratory floor.
The filament was seized near the point of departure from the quench roll and guided to engage the winder. Attempts were made without substantial success to wind the filament continuously under controlled tension. At filament tensions of 1-10 grams filament oscillations persisted causing eventual breakage. During the periods between breaks, only an unsatisfactorily loose filament winding was produced. With higher winding tensions the filament was torn apart in the solidification zone immediately as it was connected to the winder.
EXAMPLE 4
The apparatus of Example 3 was modified by provision of a nipping roller depicted as 24 in FIG. 2. The nipping roller 24 was of 4 inch overall diameter and consisted of a 4 inch diameter hollow steel cylinder of one-quarter inch wall thickness. Roller 24 comprised a 2 inch face width and was supported by a one-half inch steel shaft mounted on roller bearings. The nip roller was freely rotatable.
The chill block spinning process was started using the alloy described in Example 3. The nip roller 24 was swiveled to a position removed from chill roll 21 until the path of the centrifugally flung filament passed above and between the quench roll 21 and the nip roll 24. The nip roller was then actuated to the "closed" or converged position as shown in FIG. 2, by means of an air cylinder (not shown) which pressed the filament against the quenching wheel with a force of 5 pounds. This pressure was chosen by reference to equation (1) as explained below. The filament was seized as it passed through the nip zone and guided to engage the winder. The filament was then continuously wound without interruption at 1 pound tension. Tight uniform packages of metal ribbon 0.025 inch wide by 0.002 inch thickness were produced for 8 hours without experiencing a break.
The coefficients of dynamic friction for several metal systems are given by The Handbook of Chemistry and Physics, 51st Edition, pp F15-F17. The coefficient of friction between cast iron and steel is 0.4. The coefficient of friction between steel and a copper film (8 kg load) is given as 0.2. Taking these to be the same as the friction coefficient between the alloy spun here and the necessary steel and copper, minimum nip roll pressure was obtained from equation (1) by making the following substitutions.
T = 1.0 lbs/in.
μQR = 0.2
μNR = 0.4
from equation (1) ##EQU3##
P ≧ 1.67 lbs/in. To provide a margin of safety, the nip roll pressure was set at 5 pounds. | A method for producing and concomitantly winding continuous metal filament in which a quenching wheel is used as a quenching element and in which sufficient pressure is exerted on the filament just beyond the point of solidification to counteract the tensional stress exhibited by the winder on the filament. | 1 |
This application is a continuation of application Ser. No. 08/056,401 filed Jun. 23, 1993, now abandoned, which is a division of application Ser. No. 07/989,722, filed Dec. 11, 1992--U.S. Pat. No. 5,244,735, which is a continuation of application Ser. No. 07/694,607, filed May 2, 1991, now abandoned, which is a division of application Ser. No. 07/371,175, filed Jun. 26, 1989--U.S. Pat. No. 5,026,800.
BACKGROUND OF THE INVENTION
This invention relates to a water-absorbent resin and a process for producing this resin. In detail, it relates to a water-absorbent resin having average particle diameter in a specially defined range, narrow range of particle distribution, and a surface of uniformly improved quality and, in particular, being superior in water absorption capacity, water absorption rate, suction force, and gel strength etc., showing that water absorption properties are in good balance, showing that an amount of elution of water-soluble resin (hereinafter referred to as water-soluble component) is only small, and being very suitable as sanitary materials, and also, a process for producing the water-absorbent resin. Furthermore, this invention relates to a water-absorbent resin of a new, novel type showing angle-lacking, non-sphere, being superior in handling and treating, and having a surface of uniformly improved quality, and a process for producing the water-absorbent resin.
Hitherto, an attempt has been carried out to use a water-absorbent resin as an absorbent sanitary material for absorbing body fluids such as a sanitary cotton, a disposable diaper, and the like. There have been known, as water-absorbent resins for this purpose, a hydrolyzed starch-acrylonitrile graft polymer (Japanese Official Patent Gazette, shouwa 49-43395), a neutralized starch-acrylic acid graft polymer (Japanese Official Patent Provisional Publication, shouwa 51-125468), a saponified vinyl acetate-acrylic acid ester copolymer (Japanese Official Patent Provisional Publication, shouwa 52-14689) a hydrolyzed acrylonitrile or acrylamide copolymer (Japanese Official Patent Gazette, Shouwa 53-15959), and crosslinked products of these polymers, a crosslinked product of a partially neutralized polyacrylic acid (Japanese Official Patent Provisional Publication, Shouwa 55-84304) and others.
Incidentally, as properties to be wanted for water-absorbent resins, are cited high water absorption capacity, a water absorption rate, and high gel strength of water-contained swelling gel when the resins are coming in contact with aqueous liquid, and superior suction force to suck up water from a basic material containing aqueous liquid. These properties hitherto have been in a poor balance. That is, these properties are not in directly proportional relation, in particular, water absorption capacity and water absorption rate or gel strength and suction force are in reversely proportional relation, so that there has been found a trend that, as the water absorption capacity increases, other properties decrease. When some resins of a high water-absorbent capacity come in contact with aqueous liquid, aqueous liquid does not spread over the whole part of a water-absorbent resin and the resins form lumps, that is, what we call fish-eyes, so that an extreme lowering of a water absorption rate is observed. Also, in a case of that these water-absorbent resins are used for an absorption body of sanitary materials, the above-described water-soluble component being contained in the water-absorbent resins affects on the absorption capacity of an absorption body, liquid-spreading in a absorption body, and so on.
Especially, as the water-absorption capacity for a water-absorption resin increases, elution of a water-soluble component increases in amount, so that there has been found a problem that the resin can not properly be used as sanitary materials.
As methods to improve the above-described properties with maintaining their good balance, there have been proposed methods to improve such properties as a water absorption rate etc. by crosslinking the surface of an obtained water-absorbent resin, damaging the for water absorption capacity which the water-absorbent resin itself has. They are a method wherein a water-absorbent resin being dispersed in a hydrophilic organic solvent or a hydrophobic organic solvent in presence of water in addition with a crosslinking agent (or its aqueous solution) (Japanese Official Patent Gazette, showa 61-48521 and 60-18690) and a method wherein a water-absorbent resin powder was mixed with a crosslinking agent or a liquid composition containing a crosslinking agent with heat (Japanese Official Patent Provisional Publication, showa 58-180233, 59-189103, and 61-16903) and so on.
In these cases, of importance are uniform dispersion of a crosslinking agent over the surface of a water-absorbent resin and proper permeation into a neighborhood of the surface and, in addition, the process is of advantage to industry. However, hitherto known methods have had problems in these points. That is, in the method wherein a water-absorbent resin being dispersed in a solvent and undergoing a crosslinking reaction, a large amount of solvent is required and so, its recovery process is of disadvantage to industry. Especially, in a case being carried out in a hydrophobic organic solvent, distribution of a crosslinking agent on the surface of a water-absorbent resin is apt to become non-uniform, so that the crosslinking of surface becomes non-uniform. In the other hand, the method wherein a water-absorbent resin is mixed with a liquid component containing a crosslinking agent and treated with heat, is of great advantage to industry, and however, in a case of that particle diameter of a water-absorbent resin is small or distribution of particle diameter is broad, there was found a case that, though being affected on a treatment solution mixing with the water-absorbent resin powder, the powder meets together making a large lump (a fish-eye) and so, it is rather hard to crosslink uniformly the surface. Furthermore, though by doing these treatments such properties as water absorption rate and suction force are somewhat improved, the improvement is still insufficient and, in particular, elution of a water-soluble component could not be prevented. Thus, has not yet found a method sufficiently satisfied in point of that various kinds of properties of a water-absorbent resin are improved maintaining good balance of properties.
BRIEF SUMMARY OF THE INVENTION
Under these circumstances, the first object of this invention is to provide a water-absorbent resin, wherein the average particle diameter being in a specially defined range, the particle diameter distribution being narrow, the surface being uniformly improved, and in particular, to provide a water-absorbent resin wherein the water absorption capacity, water absorption rate, suction force, and gel strength being superior and an amount of a water-soluble component being small, and a process for producing this resin.
The second object of this invention is to provide a water-absorbent resin wherein the shape being angle-lacking, non-sphere, new and novel type, and the surface being uniformly improved in quality, and a process for producing this resin.
These objects are attained by crosslinking the surface of a water-absorbent polymer powder wherein the average particle diameter being in 100˜600 μm, the particle diameter distribution being 0.35 or less of a logarithmic standard deviation value, σ.sub.ζ, or a water-absorbent polymer powder wherein a ratio between average length and average breadth being 1.5˜20 and showing an angle-lacking, non-sphere shape.
As methods to obtain a water-absorbent polymer powder having the above-described average particle diameter and particle diameter distribution in this invention, although there have been shown, as examples, a method of an aqueous solution polymerization followed by pulverization and classification to fit in a range of the above-described average particle diameter and particle diameter distribution and a method of reverse-phase suspended polymerization under specified conditions, in order to obtain in a good yield a water-absorbent polymer powder having the above-described average particle diameter and particle diameter distribution and a new, novel shape, the most preferable method is to take a system where, when a reverse-phase suspension polymerization is carried out by using a radical polymerization initiator under conditions that a water-soluble ethylenically unsaturated monomer or its aqueous solution is suspended and dispersed in a hydrophobic organic solvent, the viscosity of an aqueous solution of the water-soluble ethylenically unsaturated monomer determined by a Brookfield rotatory viscosinmeter is adjusted in a value of 15 cps or more and a sucrose fatty acid ester and/or polyglycerol fatty acid ester are used as a dispersing agent.
In performing the above-described production process, if the viscosity defined as above is adjusted in a range of 15˜5,000 cps, is obtained in good yields a polymer powder having an average diameter of 100˜600 μm and an index (a logarithmic standard deviation) of 0.35 or less which represents particle diameter distribution.
Furthermore, in performing the above-described production process, if the viscosity defined as above is adjusted in a range of 5,000˜1,000,000 cps and, as a dispersing agent, a sucrose fatty acid esters is only used, is obtained in good yields a polymer powder wherein the ratio between length and breadth being in a range of 1.5˜20 and the shape being non-sphere without angle.
As examples of a water-soluble ethylenically unsaturated monomer constituting a water-absorbent resin in the present invention, are cited monomers of anionic character such as acrylic acid, methacrylic acid, crotonic acid, maleic acid and its anhydride, fumaric acid, itaconic acid, and 2-(meth)acryloylethanesulfonic acid, and 2-(meth)acryloylpropanesulfonic acid, and 2-(meth)acrylamido-2-methylpropanesulfonic acid, vinylsulfonic acid, styrenesulfonic acid and the like and their salts; monomers containing nonionic hydrophilic substituent such as (meth)acrylamide, N-substituted (meth)acrylamides, 2-hydroxyethyl(meth)acrylate, 2-hydroxypropyl(meth)acrylate, methoxypolyethylene glycol(meth)acrylate, polyethylene glycol(meth)acrylate and the like; monomers of cationic character such as N,N'-dimethylaminoethyl(meth)acrylate, N,N'-diethylaminoethyl(meth)acrylate, N,N'-diethylaminopropyl(meth)acrylate, N,N'-dimethylaminopropyl(meth)acrylamide, and the like and their quartary salts. These compounds can be used as alone or mixture of two or more compounds. Preferable are a kind of compound or a mixture of two or more compounds chosen from the following three groups of compounds: (meth)acrylic acid, 2-(meth)acryloylethanesulfonic acid, 2-(meth)acrylamido-2-methylpropanesulfonic acid, and their salts; and N,N'-dimethylaminoethyl(meth)acrylate and their quaternary salts; and methoxypolyethylene glycol(meth)acrylate and (meth)acrylamide. Although the monomer concentration in an aqueous monomer solution is generally variable in a wide range, the preferred range is from 20 weight % up to saturation.
The water-absorbent polymer powder used for the present invention comprises a self-crosslinking type prepared in absence of a crosslinking agent and a type co-polymerized during polymerization with a small amount of crosslinking agent, which has polymerizable unsaturated groups or reactive functional groups. As examples of the crosslinking agents are cited N,N'-methylene-bis(meth)acrylamide, N-methylol(meth)acrylamide, ethylene glycol(meth)acrylate, polyethylene glycol(meth)acrylate, propylene glycol(meth)acrylate, polypropylene glycol(meth)acrylate, glycerol tri(meth)acrylate, glycerol mono(meth)acrylate, polyfunctional metal salts of (meth)acrylic acid, trimethylolpropane tri(meth)acrylate, triallylamine, triallyl cyanulate, triallyl isocyanulate, triallyl phosphate, glycidyl(meth)acrylate. As examples of agents having reactive functional groups for example, in a case that a monomer has carboxyl and/or carboxylate group, polyhydric alcohol derivatives such as ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, glycerol, polyglycerol, propylene glycol, diethanolamine, triethanolamine, polyoxypropylene, oxyethylene-oxypropylene block co-polymer, pentaerythritol, and sorbitol; polyglycidyl derivatives such as ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, glycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyglycerol polyglycidyl ether, sorbitol polyglycidyl ether, pentaerythritol polyglycidyl ether, propyleneglycol diglycidyl ether, and polypropylene glycol diglycidyl ether; aziridine derivatives and related compounds such as 2,2-bishydroxymethylbutanol-tris[3-(1-aziridinyl)propionate], 1,6-hexamethylene-diethylene urea, and diphenylmethane-bis-4,4'-N,N'-diethylene urea; haloepoxyl compounds such as epichlorohydrin and α -methylchlorohydrin; polyaldehydes such as glutar aldehyde and glyoxal; poly amine derivatives such as ethylene diamine, diethylene triamine, triethylene tetramine, tetraethylene pentamine, pentaethylene hexamine, and polyethylene hexamine; polyisocyanates such as 2,4-toluylenediisocyanate and hexamethylenediisocyanate; polyvalent metal salts such as aluminium chloride, magnesium chloride, calcium chloride, aluminium sulfate, magnesium sulfate, and calcium sulfate. Subject to consideration upon reactivity, these crosslinking agents can be used as a mixture of more than two, but it is usually preferable to use a crosslinking agent having polymerizable unsaturated groups. An amount of use of these agents is in general about 0.001˜1.0 mol. for a water-soluble ethylenically unsaturated monomer.
The most preferable way of obtaining the polymer profitable for the present invention is that the viscosity of an aqueous solution of water-soluble ethylenically unsaturated monomer is adjusted at a value of 15 cps or more when determined with a Brookfield rotatory viscometer (25° C., 0.6 rpm) (this sort of viscosity is hereinafter referred to as, simply, viscosity) and that the reverse-phase suspension polymerization is performed using a sucrose fatty acid ester and/or a polyglycerol fatty acid ester as a dispersing agent. If the viscosity being below 15 cps, the particle obtained is small in average particle diameter and broad in distribution of particle diameter.
In a method of the present invention wherein a previously-described, specially defined dispersing agent being used, the viscosity of an aqueous solution of water-soluble ethylenically unsaturated monomer being adjusted in a range of 15˜5,000 cps, a water-absorbent polymer of sphere shape being suitable for use in the present invention and having an average particle diameter in a range of 100˜600 μm depending upon viscosity and very narrow distribution of particle diameter can be obtained. Generally under the same condition, the higher the viscosity of an aqueous solution of a monomer becomes, the larger an average particle diameter of the resin obtained becomes, and polymer of various average particle diameters can be obtained with such a simple procedure as an adjustment of viscosity.
Although a preferable average particle diameter of a water-absorbent resin obtained is different depending upon a use, for instance, in a case being used an sanitary materials, the average particle diameter is usually in a range of 100˜600 μm, more preferably about 150˜400 μm. The particle of this kind is obtainable when the viscosity of an aqueous solution being adjusted in a range of 15˜5,000 cps, more preferably 20˜3,000 cps. In addition, a water-absorbent polymer obtained according to this method shows very narrow distribution of particle diameter.
For instance, when particle distribution is plotted in a logarithmic probability paper, a value of logarithmic standard deviation (σ.sub.ζ), which is an index showing uniformity of a particle, is 0.35 or less, in a more preferable case 0.30 or less, that is narrow particle distribution not yet obtained by any previous method.
In the other side, when the viscosity of an aqueous solution of water-soluble ethylenically unsaturated monomer is adjusted in a range of 5,000˜1,000,000 cps, although dependent upon stirring condition, the particles obtained show that the ratio between average length and average breadth for particles as defined as below-described is in a range of 1.5˜20, and an angle-lacking and non-sphere, so to speak, Vienna sausage-like shape. This polymer has length of 100˜10000 μm, more preferably 1000˜10000 μm and breadth of 10˜2000 μm, more preferably 100˜2000 μm, and a ratio between average length and average breadth being in a range of 1.5˜20, so that it is easy in handling and treating in point of that it is hard for this polymer to fall off from basis materials, and the range of the combination with different basis materials is spread. The diameters to represent a shape of water-absorbent polymer are defined as follows. ##STR1##
Although being in a range of 5,000 cps or more, when the viscosity is in a range of 5,000˜20,000 cps, a non-sphere polymer and a sphere polymer are obtained as a mixture and, when the viscosity is higher than 20,000 cps, a non-sphere polymer is only obtained. Furthermore, when the viscosity is higher than 1,000,000 cps, there is sometimes accompanied by difficulty when an aqueous solution of monomer being supplied for a reaction vessel.
As the thickener used for adjusting viscosity as described above, are cited hydroxyethylcellulose, hydroxypropylcellulose, methylcellulose, carboxymethylcellulose, polyethylene glycol, polyacrylamide, polyethyleneimine, polyacrylic acid, partially neutralized polyacrylic acid, crosslinked polyacrylic acid, partially neutralized, crosslinked polyacrylic acid, dextrin, and sodium arginate so on. Preferable are hydroxyethylcellulose, polyacrylamide, polyacrylic acid, partially neutralized polyacrylic acid, crosslinked polyacrylic acid, partially neutralized, crosslinked polyacrylic acid. Very specially preferred for a water absorbent-resin having a new shape is hydroxyethylcellulose. For use of a water-soluble, partially neutralized polyacrylic acid, the viscosity of its 5% aqueous solution is preferred when it is 30 cps or more. For use of a water-insoluble, crosslinked product, is preferred the one whose particle diameter is about 30 μm or less and powder-like.
To thicken an aqueous solution to a designated viscosity by using these thickener, it is preferred that the thickener is generally used in a range of 0.05˜20 weight % to a monomer, although the percentage is variable with the kind and concentration of a monomer and the kind and molecular weight of a thickener.
In the other side dispersing agents used in this case are sucrose fatty acid esters and/or polyglycerol fatty acid esters. As the former sucrose fatty acid esters, are cited mono-, di-, and triesters derived from sucrose with more than one aliphatic acid chosen from stearic acid, palmitic acid, lauric acid, and oleic acid. As the latter polyglycerol fatty acid esters, are cited mono-, di-, and triesters derived from polyglycerin of condensation degree 10 or less with, at least, one aliphatic acid chosen from stearic acid, palmitic acid, lauric acid, oleic acid, and ricinolic acid. Among all these nonionic surface active agents, most preferable are those indicating HLB of 2˜6. The amount of a dispersing agent for use is generally 0.05˜10 weight %, more preferably 0.5˜5 weight % against the amount of a water-soluble ethylenically unsaturated monomer. To obtain the water-absorbent polymer having a new non-sphere shape without angle, that is one of the polymers suitable for use in the present invention, the sucrose fatty acid esters can be only used and, if other kinds of dispersing agents are used, this novel type of resin is not obtained.
As an inert hydrophobic organic solvent used for the present invention are cited, for example, aliphatic hydrocarbons such as n-pentane, n-hexane, n-heptane, and n-octane; cycloaliphatic hydrocarbons such as cyclohexane, cyclooctane, methylcyclohexane, decaline, and their derivatives; aromatic hydrocarbons such is benzene, ethylbenzene, toluene, xylene, and their substituted derivatives; and halogenated hydrocarbons such as chlorobenzene, bromobenzene, carbon tetrachloride, and 1,2-dichloroethane. These agents can be used as alone or a mixture of two kinds or more. Specially preferable are n-hexane, n-heptane, cyclohexane, methylcyclohexane, toluene, xylene, and carbon tetrachloride.
The ratio of an organic solvent to a water-soluble ethylenically unsaturated monomer is generally suitable as 1:1˜5:1 from standpoints of steady dispersion and removal of heat generated during polymerization and temperature control.
As an initiator for radical polymerization in the present invention, any kind of conventional agent can be used without limitation, but particularly, water-soluble ones are preferred. More concretely, for example, persulfates such as potassium persulfate, sodium persulfate, and ammonium persulfate; hydroperoxides such as hydrogen peroxide, t-butyl hydroperoxide, and cumene hydroperoxide; azo compounds such as 2,2'-azo-bis-2-amidinopropane dihydrochloride etc. are cited. These polymerization initiators can be used as a mixture of more than two agents. Furthermore, a redox type initiator prepared by combination of these polymerization initiators and reducing agents such as sulfite, L-ascorbic acid, and ferric salts may also be used.
In the case where above-described reverse-phase suspension polymerization is performed to obtain a water-absorbent polymer used for the present invention, if it is followed by a drying process, a water-absorbent polymer obtained can be taken out as a bead-like or Vienna sausage-like particle. As this drying process, there are methods wherein water is distilled off as an azeotropic mixture with a hydrophobic organic solvent used in polymerization and wherein filtration of a water-containing gel followed by drying with conventional drying apparatus due to heated wind, reduced pressure, or fluid bed is carried out.
To obtain a polymer powder usable in this invention, not only the above-described reverse-phase suspension polymerization, but also an usable condition is that, when a water-containing gel obtained from an aqueous solution polymerization known in public is dried, pulverized, and classified, the average particle diameter is adjusted in a range of 100˜600 μm and the particle diameter distribution is adjusted at a value of 0.35 or less of σ.sub.ζ.
This invention is attained with uniform quality improvement of a polymer surface by means of surface-crosslinking in a previously known method where the polymer having an average particle diameter in a specially defined range, a narrow distribution of particle diameters, and a sausage shape are obtained according to the above-described method.
A more preferable method is that a polymer powder obtained by drying up to less than 10 weight % of water content is mixed with 0.005˜20 weight % of a crosslinking agent (against the polymer powder) having a reactive group of two or more in its molecule for a functional group in the powder, a reaction is carried out with heating, and said polymer powder is crosslinked in a neighbor of the surface. When the crosslinking agent and the polymer powder being mixed, it is permitted to contain water and a hydrophilic organic solvent.
When this surface-crosslinking treatment is being performed, if the treatment condition is chosen from specially defined ones, the treatment effect becomes superior and an advantage of this process increases. That is, a polymer powder of water content of less than 10 weight % is mixed with a treatment solution composed of 0.005˜20 weight % (more preferable 0.005˜5 weight %) of a crosslinking agent to the polymer powder, 0.1˜5 weight % of water, and 0.01˜6 weight % of hydrophilic organic solvent, and thereby, the surface and its neighborhood of polymer power is crosslinked.
When the polymer powder having been obtained from the previously-described procedure, having an average particle diameter in the specially defined range, and showing narrow distribution of particle diameter is mixed with a treatment solution containing a crosslinking agent, any fish eye is not formed, the treatment solution is uniformly dispersed on the surface of the polymer powder, and appropriately permeated in a neighborhood of the polymer powder surface, and as a result, the crosslinking is performed uniformly and with good efficiency. Thus, is obtained a water-absorbent resin wherein water-absorption capacity being high, water-absorption rate and suction force being superior, elution of a water-soluble composition from the resin being small in amount, and as a sanitary material, being very suitable.
In the above described crosslinking process for producing a water-absorbent resin in this invention it is first preferred to maintain water content of the polymer at a value less than 10%, more preferably less than 7% by the similar process as the above-described one, which was obtained with reverse-phase suspension polymerization. In a case of water content 10% or more, when a crosslinking agent or the treatment solution containing this is mixed, in addition to that the mixing character is inferior, the crosslinking agent sometimes super-permeates an inside of the resin, so that a water-absorbent resin obtained sometimes has small water-absorption capacity.
As a crosslinking agent, which is able to use in this invention, although unlimited as far as it is a compound having two or more of a functional group reactive with functional groups existing in the polymer, are preferred hydrophilic, more preferred water-soluble compounds. For examples, in a case that the polymer has a carboxyl and/or carboxylate group as a functional group, are cited polyhydric alcohols such as ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, glycerol, polyglycerol, propylene glycol, diethanolamine, triethanolamine, polyoxypropylene, oxyethyleneoxypropylene block copolymer, pentaerythritol, and sorbitol; polyglycidyl compounds such as ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, glycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyglycerol polyglycidyl ether, sorbitol polyglycidyl ether, pentaerythritol polyglycidyl ether, propylene glycol diglycidyl ether, and polypropylene glycol diglycidyl ether; polyaziridine derivatives such as 2,2'-bishydroxymethylbutanol-tris [3-(1-aziridinyl)propionate], 1,6-hexamethylenediethylenyl urea, and diphenylmethane-bis-4,4-N,N'-diethylenyl urea; haloepoxy compounds such as epichlorohydrine and α-methylchlorohydrine; polyaldehydes such as glutal aldehyde and glyoxal; polyamine derivatives such as ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine, and polyethyleneimine; polyisocyanates such as 2,4-toluylenediisocyanate and hexamethylenediisocyanate; polyvalent metal salts such as aluminium chloride, magnesium chloride, calcium chloride, aluminium sulfate, magnesium sulfate, and calcium sulfate. Particularly preferable are polyhydric alcohols, polyglycidyl compounds, polyamine derivatives, and polyvalent metal salts. The amount of use of these hydrophilic crosslinking agent is 0.005˜20 weight % against a polymer powder, preferable 0.005˜5 weight %, more preferable 0.01˜1 weight %. In a case that this amount is less than 0.005 weight %, an effect of surface treatment does not appear and also, even if it is used in amount more than 20 weight %, there are some cases where an effect corresponds to amount of use of crosslinking agent does not appear and the water absorption capacity remarkably decreases.
In the present invention, if a crosslinking agent is mixed with polymer powder, it is preferable for increase of the treatment effect that the above-described treatment solution containing water and an organic solvent is used. In this case, the amount of water composing a treatment solution is 0.1˜5 weight % against a polymer powder. If this amount is less than 0.1 weight % a crosslinking agent is not easily permeated in the neighborhood of the polymer powder surface, so that a crosslinking surface layer does not properly form. Also, there are some cases where if it exceeds 5 weight %, the agent permeats in excess, so that the water absorption capacity decreases.
As a hydrophilic organic solvent used in the treatment solution, it is not particularly limited as long as it can dissolve a crosslinking agent and does not affect the performance of a water-absorbent resin. As such, for examples, are cited lower alcohols such as methanol, ethanol, n-propanol, isopropanol, and n-butanol; ketones such as acetone and methylethylketone; ethers such as dioxane and tetrahydrofuran; amides such as N-N'-dimethylformamide; sulfoxides such as dimethylsulfoxide. The amount of use of a hydrophilic organic solvent is 0.1˜6 weight %. In a case that the amount of use of a hydrophlic organic solvent is less than 0.1 weight %, mixing of a polymer with the treatment solution becomes nonuniform and also, if the amount exceeds 6 weight %, an effect corresponding to the amount of use can not be obtained and only expense increases, so that it is not industrially favorable. Although dependent upon the kind of hydrophilic organic solvents, it is generally preferable to use 0.3˜4 weight % against a water-absorbent resin.
As a method to mix a treatment solution containing a crosslinking agent with a polymer powder in this invention, it is general to spray or drop and mix the treatment solution for a polymer powder. As a mixer used for mixing, although is preferred the one having a big mixing power to mix uniformly, conventional mixer and kneader can be used. For examples, are cited a cylinder mixer, a double cone mixer, a V-type mixer, a ribbon mixer, a screw mixer, a fluidized mixer, a rotating-disc type mixer, an air mixer, a double-arm type kneader, an internal mixer, a muller kneader, a roll mixer, and a screw extruder etc. To warm up a composition obtained with mixing a treatment solution containing these crosslinking agents with a polymer ponder, a conventional dryer or heating furnace can be used. For examples, are cited a gutter stirring dryer, a rotating dryer, a disc dryer, a kneading dryer, a fluidized dryer, an air dryer, an infrared light dryer, and an dielectrically heating dryer. Temperature for heating treatment is in a range of 40˜250° C., more preferable 80˜200° C.
The water-absorbent resin obtained from the production process in this invention has an average particle diameter in a specially defined range and a narrow distribution of particle diameter and also, has high water absorption capacity and a superior water absorption rate and suction force. In addition, since a water-soluble component existing in the inside of the resin is only eluted in a very small amount from a surface of the resin, the resin is very superior, in particular, in a dispersion character of liquid and in safety when being used as sanitary materials. This kind of water-absorbent resin, as mentioned above, is possible to be produced in the best yield and with high efficiency in the case of that an aqueous solution of water-soluble ethylenically unsaturated monomer, of which viscosity is adjusted at a specially defined value by using a thickener, undergoes a reverse-phase suspension polymerization using a sucrose fatty acid ester and/or polyglycerol fatty acid ester as a dispersing agent and a polymer obtained is dried and, mixed and warmed with a treatment solution containing a crosslinking agent of a specially defined composition.
Also, such a method involving treatment of a surface part like this case does not require a large amount of organic solvent, so that it is of advantage to economy and industry and a superior water-absorbent resin being of high safety as a sanitary material and various kinds of water-holding materials became obtainable in a method very useful for producing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an optical microphotograph to represent a particle structure of the water-absorbent resin of a sphere shape (A16) obtained from example 6.
FIG. 2 is an optical microphotograph to represent a particle structure of the water-absorbent resin of a vienna sausage shape (A18) obtained from example 8.
FIG. 3 is an optical microphotograph to represent a particle structure of the water-absorbent resin (B12) obtained from example for comparison 3.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLES
Although the present invention is explained in detail with the examples described below, a range of the present invention is not defined within the examples.
The water absorption performance of water-absorbent resin is determined according to the procedure shown below.
(1) Average Particle Diameter and Distribution of Particle Diameter
The resin powder is sifted and classified by using JIS standard sieves (20, 32,48, 60, 100, 145, 200, and 350 mesh) and then, the remaining percentage of resin remaining on the mesh (R %) is plotted on a logarithmnic probability paper. Average diameter is represented by a particle diameter corresponding to R for 50%.
The particle distribution is represented by using logarithmic standard deviation, σ.sub.ζ, as an index, which is derived from the following equation: ##EQU1## Here, it is meant that, as the value of σ.sub.ζ becomes smaller, the particle distribution becomes more uniform.
(2) Water Absorption Capacity
The water-absorbent resin, 0.2 g, is uniformly put into a tea bag-like bag (40 mm×150 mm) made by a nonwoven fabric, and soaked in a 0.9 weight % aqueous solution of sodium chloride. The teabag-like bag is taken out after 10 minutes and 30 minutes, respectively, and stood for draining for a designated time. Then, the weight is determined and the water absorption capacity is calculated by the following equation. Further, when only the tea bag being soaked, the weight obtained after water absorption is taken as a blank.
Water absorption capacity (g/g)=(weight of bag after absorption--blank)/(weight of water-absorption resin)
(3) Water Absorption Rate
To 20 ml of synthetic urine containing 1.9 weight % of urea, 0.8 weight % of sodium chloride, 0.1 weight % of calcium chloride, and 0.1 weight % of magnesium sulfate is added 1.0 g of a water-absorbent resin. The water absorption rate is defined with time passed until the water-absorbent resin absorbing the synthetic urine losts the flowing character of swelling gel.
(4) Suction force
Water--absorbent resin, 1.0 g, is placed on a material containing synthetic urine, prepared by adding 20 ml of synthetic urine on a tissue paper of size 55 mm×75 mm. After standing for 10 mm, a gel swelled is taken and weighed. The weight is defined as suction force of the resin from the tissue paper. At the same time, the presence of a fish-eye of the added water-absorbent resin was examined.
(5) Amount of Water-Soluble Component Eluted from Resin Surface
A disposable diaper for child composed of a nonwoven fabric, cotton-like pulp, a water-absorbent paper, and a waterproof film (having a weight of 72 g) is cut in half and 2.5 g of a polymer is uniformly scattered between the cotton-pulp and the water-absorbent paper and to this, 120 ml of the above-described synthetic urine is added, and the thus-prepared sample is stood for 16 hours at 37° C. After standing for 16 hours, the cotton-like pulp is only taken and a water-soluble component transferred from the pulp is extracted with 1,000 ml of pure water. This extract solution is filtered and a polymer component contained in this filtered solution is measured by using an acid-base titration method and thus, a total amount of a water-soluble component eluted is determined against the amount of water-absorbent resin as weight %.
Example 1
In a four-necked separable 2 L flask equipped with a stirrer, a reflux condenser, a thermometer, an inlet tube for nitrogen gas, and a dropping funnel was placed 1,000 ml of cyclohexane and dissolved 4.0 g of a sucrose fatty acid ester (DK-ESTER F-50, HLB=6, a product from DAIICHI KOGYO SEIYAKU Co., LTD.) and nitrogen gas was introduced into this solution to remove oxygen dissolved. In another flask containing a solution of 84.6 g of sodium acrylate, 21.6 g of acrylic acid, and 0.016 g of N,N'-methylene-bisacrylamide in 197 g of ion-exchanged water was dissolved 0.53 g of hydroxyethylcellulose (HEC-DAISERU EP-850, a product from DAISERU CHEMICAL Co., LTD.) and was prepared a monomer solution adjusted at a monomer concentration of 35 weight % and viscosity of 40 cps. To this monomer solution was dissolved 0.15 g of potassium persulfate and then, nitrogen gas was introduced to remove oxygen dissolved in this aqueous solution.
Next, to the above separable flask solution was added the aqueous monomer solution in the latter flask and the mixture obtained was dispersed with stirring at 230 rpm. Then, polymerization reaction was initiated by raising bath temperature to 60° C. and completed by maintaining this temperature for 2 hours. After polymerization, the reaction mixture was treated by an azeotropic distillation with cyclohexane to remove water in the water-containing gel, filtered, and dried at 80° C. under reduced pressure to obtain a polymer powder of sphere shape (A01). Water content for this polymer powder was 5.6%.
With 100 weight parts (weight parts are hereinafter referred to as parts) of the polymer powder (A01) was mixed by a paddle type mixer a treatment solution composed of 0.3 parts of diethylene glycol, 4 parts of water, and 0.5 parts of isopropanol. When mixing, any large lump is not formed and all the composition passed through a 20 mesh metal net (mesh of 840 μm) when tried. The composition obtained was treated with heat by a paddle type dryer at 180° C. for 1 hour to obtain a water-absorbent resin (A11). Results obtained from properties measurements for this resin are shown in table 1.
Example 2
Except the use of 2.2 g of hydroxyethylcellulose (SP-600, a product from DAISERU CHEMICAL Co., LTD.), a polymerization reaction was carried out under the same conditions to those for example 1. Viscosity of the monomer aqueous solution was 800 cps and water content of a polymer powder of sphere shape (A02) was 6.8%. With 100 parts of the polymer powder (A02) was mixed by a paddle type mixer a treatment solution composed of 0.1 parts of ethylene glycol digilycidyl ether, 3 parts of water, and 6 parts of methanol. When passing is tried, all the composition passed through a 20 mesh metal net. The composition obtained was treated with heat by a paddle type dryer at 100° C. for 1 hour to obtain a water-absorbent resin (A12). Results obtained from properties measurements for this resin are shown in table 1.
Example 3
Except the use of 3.5 g of hexaglycerol-condensed ricinolate (STEP RP-6, a product from KAO Co., LTD.), a polymerization reaction was carried out in the same way as in example 1 to obtain a polymer powder of sphere shape (A03), which showed water content of 6.3%. With 100 parts of the polymer powder (A03) was mixed by a V-type mixer a treatment solution composed of 0.08 parts of epichlorohydrin, 2 parts of water, and 4 parts of methanol. When tried, all the composition passed through a 20 mesh metal net and a lump is not observed which may be formed when mixing. The composition obtained was treated with heat by a paddle type dryer at 100° C. for 1 hour to obtain a water-absorbent resin (A13). Results obtained from properties measurements for this resin are shown in table 1.
Example 4
In a four-necked separable 2 L flask equipped with a stirrer, a reflux condenser, a thermometer, an inlet tube for nitrogen gas, and a dropping funnel was placed 1,000 ml of cyclohexane and dissolved 4.0 g of a sucrose fatty acid ester (DK-ESTER F-20, a product from DAIICHI KOGYO SEIYAKU Co., LTD.), and nitrogen gas was introduced into this solution to expel oxygen dissolved. In another flask, 65.8 g of sodium acrylate, 21.6 g of acrylic acid, 0.076 g of polyethylene glycol diacylate (n=14), and 15 g of sodium polyacrylate (AQUALIC OM-100, a product from NIPPON SHONUBAI KAGAKU KOGYO Co., LTD., viscosity of 150 cps at 25° C. for a 5% aqueous solution) was dissolved in 250 g of ion-exchanged water to prepare an aqueous monomer solution of viscosity of 20 cps.
Next, into this solution, 0.12 g of sodium persulfate was dissolved and a reaction procedure was carried out in the same way as that for example 1 to obtain a polymer powder of sphere shape (A04), which showed water content of 4.8%.
With 100 parts of the polymer powder (A04) mixed by a paddle type mixer a treatment solution composed of 1 part of glycerol, 5 parts of water, and 1 part of isopropanol fill the composition passed through a 20 mesh metal net and any lump is not formed at the mixing. Then, the composition obtained was treated with heat by a paddle type dryer at 180° C. for 1.5 hours to obtain a water-absorbent resin (A14). Results obtained from properties measurements for this resin are shown in table 1.
Example 5
Except the use of sodium polyacrylate (AGUALIC FH, 2×10 4 cps at 25° C. for viscosity of 1% aqueous solution, a product from NIPPON SHOKUBAI KAGAKU KOGYO Co., LTD.) as a thickener, a reaction procedure was carried out in the same way as that for example 4 to obtain a polymer powder of sphere shape (A05), showing water content of 5.8%. The viscosity of an aqueous monomer solution was 27 cps. With 100 parts of the polymer powder (A05) was mixed by a ribbon type mixer a treatment solution composed of 0.05 parts of glycerol glycidyl ether, 4 parts of water, and 0.8 parts of ethanol. All the composition passed through a 20 mesh metal net and, when mixing, any lump did not form. The composition obtained was treated with heat in a fluidized bed dryer at 100° C. for 1 hour to obtain a water-absorbent resin (A15). Results obtained from properties measurements for this resin are shown in table 1.
Example 6
Except that the amount of hydroxyethylcellulose (HEC-DAISERU EP-850, a product from DAISERU KAGAKU KOGYO Co., LTD.) in example 1 was changed into 1.6 g and the viscosity of aqueous monomer solution was adjusted at 2,000 cps), a polymerization reaction was carried out in the same way as that for example 1 to obtain 0.6 g of a water-absorbent polymer powder o all sphere shape (A06), which showed water content of 6.4%. In the same way as carried out for example 1, this polymer powder (A06) was treated with a surface crosslinking to obtain a water-absorbent resin (A16). Results obtained from properties measurements for this resin are shown in table 1.
Example 7
Except that the amount of hydroxyethylcellulose (HEC-DAISERU SP-600, a product from DAISERU KAGAKU KOGYO Co., LTD.) was 0.3 g and the viscosity of aqueous monomer solution was adjusted at 17 cps, a polymerization reaction was carried out in the same way as that for example 2 to obtain a water-absorbent polymer powder of sphere shape (A07) which showed water content of 5.9%. In the same way as carried out for example 1, this polymer powder (A07) was treated with a surface crosslinking to obtain a water-absorbent resin (A17). Results obtained from properties measurements for this resin are shown in table 1.
Example 8
In a four-necked separable 2 L flask equipped with a stirrer, a reflux condenser, a thermometer, an inlet tube for nitrogen gas, and a dropping funnel is placed 1,000 ml of cyclohexane and dissolved 4.0 g of a sucrose fatty acid ester (DK-ESTER F-50, a product from DAIICHI KOGYO SEIYAKU Co., LTD., HLP=6) and nitrogen gas was introduced into this solution to remove oxygen dissolved. In another flask containing a solution of 84.6 g of sodium acrylate, 21.6 g of acrylic acid, and 0.016 g of N,N'-methylene-bisacrylamide in 197 g ion-exchanged water was dissolved 3.2 g of hydroxyethylcellulose (HEC-DAISERU EP-850, a product from DAISERU CHEMICAL Co., LTD.) and was prepared an aqueous monomer solution adjusted at a monomer concentration of 35 weight % and viscosity of 35,000 cps. To this aqueous monomer solution was dissolved 0.15 g of potassium persulfate and then, nitrogen gas was introduced to remove oxygen dissolving in this aqueous solution.
Next, to the above separable flask solution was added the aqueous monomer solution in the latter flask and the mixture obtained was dispersed with stirring at 230 rpm. Then, polymerization reaction was initiated by raising bath temperature to 60° C. and completed by maintaining this temperature for 2 hours. After polymerization completed, the reaction mixture was treated by an azeotropic distillation with cyclohexane to remove water in the water-containing gel, filtered, and dried at 80° C. under reduced pressure to obtain a polymer powder (A08), which had average length of 3,000 μm and average breadth of 550 μm and showed somewhat long and narrow shape of Vienna sausage type. Besides, any sphere particle did not exist.
This polymer powder (A08) was treated with surface crosslinking in the same way as that for example 1 to obtain a water-absorbent resin (A18). Results obtained from properties measurements for this resin are shown in table 1.
Example 9
Except that the amount of a thickener, hydroxyethylcellulose (EP-850 a product of DAISERU KAGAKU KOGYO Co., LTD.) was changed into 5.3 g, polymerization reaction was carried out in the same way as that for example 8. Viscosity of the aqueous monomer solution was 240,000 cps. After the polymerization completed, treatment with an azeotropic dehydration followed by filtration and drying under reduced pressure gave a polymer powder (A09) having average length of 3500 μm and average breadth of 600 μm and showing a long and narrow shape of Vienna sausage type. Any sphere particle did not exist. This polymer powder (A09) was treated with surface crosslinking in the same way as that for example 2 to obtain a water-absorbent resin (A19). Results obtained from properties measurements for this resin are shown in table 1.
Example 10
Into 329 g of ion-exchanged water was dissolved 141 g of sodium acrylate, 36.1 g of acrylic acid, and 0.118 g of N,N'-methylen-bisacrylamide and, a static aqueous solution polymerization was carried out at 55˜80° C. under a nitrogen atmosphere by using 0.68 g of ammonium persulfate and 0.025 g of sodium hydrogensulfite to obtain a gel-like water-containing polymer, which was dried at 180° C. with a heated wind dryer, pulverized with a hammer-type pulverizer, and sieved with a 28 and a 60 mesh metal nets. The portion, which passed the 28 mesh net but not the 60 mesh net, was taken as a pulverized polymer powder (A010). Treatment of this polymer powder (A010) by surface crosslinking performed in the same way as that for example 1 gave a water-absorbent resin (A110). Results obtained from properties measurements for this resin are shown in table 1.
Example for Comparison 1
Properties of the polymer powder (A01) obtained from example 1 were measured and summarized in table 1.
Example for Comparison 2
Except that 3.5 g of sorbitane monostearate (REODOL SP-S10, a product from KAO Co., LTD.) was used as a dispersing agent instead of a sucrose fatty acid ester, a polymerization procedure was carried out in the same way as for example 1 to obtain a polymer powder for comparison (B01), which had water content of 6.2%. The polymer powder for comparison (B01) obtained was mixed with a liquid composition, which is the same as used for example 1, by a paddle type mixer. When mixing, were formed lumps in 8.6%, which did not pass through a 20 mesh metal net. The composition obtained was treated with heat at 180° C. for 1 hour by using a paddle dryer to obtain a water-absorbent resin for comparison (B11). Results obtained from properties measurements for this resin are shown in table 1.
Example for Comparison 3
Except no addition of hydroxyethylcellulose to a aqueous monomer solution, the same procedure as for example 1 was carried out to obtain a polymer powder (B02), which showed water content of 4.7%. At this time, viscosity of a aqueous monomer solution was 7 cps.
The polymer powder for comparison (B02) was mixed by a paddle type mixer with a liquid composition same as used in example 2. When mixing, were formed lumps in 8.2% which did not pass through a 20 mesh metal net. The composition obtained was treated with heat by a fluidized bed dryer at 100° C. for 1 hour to obtain a water-absorbent resin for comparison (B12). Results obtained from properties measurements for this resin are shown in table 1.
Example for Comparison 4
Except that 4.0 g tetraglycerol monostearate (POEMU J-4010, a product from RIKEN VITAMIN Co., LTD.) was used as a dispersing agent instead of a sucrose fatty acid ester used in example 1 and hydroxyethylcellulose was not added to the aqueous monomer solution, a procedure same as for example 1 was carried out to obtain a polymer powder (B03), which showed water content of 5.9%.
The polymer powder for comparison (B03) was mixed with a liquid composition, which is the same as used for example 1, by a paddle type mixer. When mixing, were formed lumps in 7.6% which did not pass through a 20 mesh metal net. The composition was treated with heat by a paddle dryer at 180° C. for 1 hour to obtain a water-absorbent resin for comparison (B13). Results obtained from properties measurements for this resin are shown in table 1.
Example for Comparison 5
Properties measured for the polymer powder (A08) in example 8 are shown in table 1.
Example for Comparison 6
In example 10, taking only a part passed through a 28 meth metal net, a polymer powder for comparison (B04) was obtained. Treatment of this polymer powder for comparison (B04) with surface-crosslinkage gave a water-absorbent resin for comparison (B14). Results obtained from properties measurements for this resin are shown in table 1.
TABLE 1 - Water- Average Particle Water soluble particle diameter Amount Water absorption absorption Suction Formation of component Water-absorbed resin diameter distribution of lump capacity (g/g) rate force fish-eye eluted obtained (μm) σζ (%) 10 min. 30 min. (sec.) (g) * (%) Example 1 Water-absorbent resin (A11) 400 0.16 0 59 65 21 18.0 ⊚ 0.15 Example 2 Water-absorbent resin (A12) 500 0.11 0 54 60 33 17.9 ⊚ 0.08 Example 3 Water-absorbent resin (A13) 300 0.15 0 57 63 28 18.8 ⊚ 0.12 Example 4 Water-absorbent resin (A14) 350 0.18 0 60 67 22 18.7 ⊚ 0.07 Example 5 Water-absorbent resin (A15) 350 0.17 0 59 65 19 18.2 ⊚ 0.05 Example 6 Water-absorbent resin (A16) 550 0.19 0 47 64 42 17.6 ⊚ 0.09 Example 7 Water-absorbent resin (A17) 150 0.24 0 52 60 18 18.2 ⊚ 0.13 Example 8 Water-absorbent resin (A18) sausage-like shape 0 35 51 52 16.2 ⊚ 1.21 Example 9 Water-absorbent resin (A19) sausage-like shape 0 38 54 49 16.3 ⊚ 0.99 Example 10 Water-absorbent resin (A110) 280 0.16 0 43 62 38 17.8 ⊚ 1.82 Example for comparison 1 Polymer powder (A01) 400 0.16 -- 44 62 65 13.2 ◯ 4.2 Example for comparison 2 Water-absorbent resin for comparison (B11) 80 0.43 8.6 45 56 49 15.2 Δ 3.5 Example for comparison 3 Water-absorbent resin for comparison (B12) 100 0.41 8.2 41 53 45 15.1 Δ 3.1 Example for comparison 4 Water-absorbent resin for comparison (B13) 150 0.40 7.6 43 55 47 14.8 Δ 3.3 Example for comparison 5 Water-absorbent resin for comparison (A08) sausage-like shape -- 28 50 97 11.3 ◯ 4.9 Example for comparison 6 Water-absorbent resin for comparison (B14) 230 0.58 3.5 38 59 47 15.0 Δ 5.1 (Note) *⊚: No formation of fisheye at all. ◯: Nearly no formation of fisheye. Δ: Some formation of fisheye. | A process for producing water-absorbent resins having an average particle diameter of 100 to 600 μm and a particle diameter distribution of 0.35 or less by polymerizing an aqueous solution of a water-soluble ethylenically unsaturated monomer, pulverizing and sieving the polymer so obtained, and crosslinking the surface of the polymer powder. | 8 |
BRIEF SUMMARY OF THE INVENTION
Heretofore, rigid receptacles for body drainage have been utilized, as well as plastic receptacles which were inserted in a reusable cannister and then disposed of, either full or empty. While these have proved quite satisfactory, some institutions desire a self-sustaining rigid container. Accordingly, it is the object of this invention to provide an economical self-sustaining rigid container that may be asceptically disposed of with or without drainage therein.
The invention comprises upper and lower sections each tapered so that the sections may be nested during shipping and storage for space saving purposes. When assembled, the upper and lower sections taper in opposite directions. The lower section has a closed bottom and open top while the upper section has an open lower end, the upper end being closed except for fittings opening therethrough for connection to a vacuum line and to a patient. The larger ends of each section are provided with an annular arrangement of complemental interlocking parts which, when pressed together, establish a fluid tight seal between the sections, and the sections cannot be separated thereafter without being broken. The drainage receiver may be used with or without a valve to protect the vacuum system from contamination, as may be preferred. The receiver may be emptied, if desired, or disposed of with drainage therein in an asceptic manner. If the valve shows contamination, it may be disposed along with the receiver.
The invention also contemplates the use of an intermediate section equipped to interlock with both the section therebelow and the one thereabove in a fluid tight manner, if an extra large amount of drainage is expected. The parts of the entire apparatus are simple, easy to assemble, and the receiver or collector may be emptied and reused for the same patient.
Many other advantages, features and additional objects of the present invention will become manifest to those versed in the art upon making reference to the description and the accompanying sheets of drawings in which a preferred structural embodiment incorporating the principles of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
ON THE DRAWINGS:
FIG. 1 is a diagrammatic view of a drainage collector embodying principles of the instant invention shown mounted in operative position and connected to both a vacuum source and a patient;
FIG. 2 is an enlarged view of the assembled device illustrating how a valve may be connected thereto and showing fittings for accommodating both the tubing to the vacuum source and the tubing to the patient;
FIG. 3 is a fragmentary plan view indicating how the device may be disposed as asceptically;
FIG. 4 is a view of a tubular fitting which may be utilized to connect the valve to the vacuum line, or make a connection to the vacuum line without the valve;
FIG. 5 is a vertical sectional view of the device with the upper and lower portions connected;
FIG. 6 is a view of the upper and lower portions in nested relationship as they would be when shipped or stored;
FIG. 7 is a greatly enlarged fragmentary sectional view showing the connection between two sections of the device;
FIG. 8 is an elevational view of an intermediate section which may be disposed between the sections seen in FIG. 5 to enlarge the capacity of the device; and
FIG. 9 is a fragmentary part sectional part elevational view of the structure of FIG. 8.
DETAILED DESCRIPTION
In FIG. 1 there is a diagrammatic showing of a drainage receptacle, generally indicated by numeral 1, mounted in operative position upon a stand 2 with a vacuum line 3 leading from the receiver 1 to a plug-in part 4 in the wall which connects with the source of vacuum, as is customary in hospitals and similar institutions. Vacuum line may, of course, lead to some other source of vacuum such as an individual pump, if occasion warrants any such installation.
A tube 5 also leads from the receiver 1 to the body of a patient 6 lying prone upon a bed 7. Drainage from the body of the patient is drawn into the receiver 1 through the line 5 due to suction inside the receiver by way of the line 3. A valve 8 may be interposed between the receiver 1 and the main suction line 3 in order to prevent contamination of the vacuum system in the event the receiver fills beyond a certain point.
Preferably, but not essentially, the valve 8 is like that set forth, described and claimed in our U.S. Pat. No. 3,863,634 entitled, "Asceptic Suction System for Body Fluids and Valve Therefor", and dated Feb. 4, 1975.
In FIGS. 2 and 5, the drainage receptacle 1 is shown assembled. Initially the drainage receptacle is in separate sections, an upper section 9 and a lower section 10. Both sections are tapered, the upper section 9 narrowing upwardly and the lower section 10 narrowing downwardly when assembled so that the assembled structure has somewhat the shape of a barrel. The lower section 10 has a closed bottom and an open top. The upper section 9, when assembled, has an open bottom and a top closed except for two tubes 11 and 12.
The tube 11, which for convenience sake may be termed the patient's tube, extends through the top of the section 9, and inside the top of this section, the tube is substantially half cut away on the side nearest the section wall as indicated at 13 in FIG. 5. This is to guide incoming drainage toward the section wall and the cut of the tube extends substantially flush with the inside of the top of the casing to control splash and foaming, and also to prevent siphoning of drainage back to the patient from the receiver should the collective drainage rise high enough to otherwise effect that result.
One leg of a nipple 14 is inserted in the portion of the tube 11 outside of the casing, and the other leg of that nipple is connected to the patient's line 5 of FIG. 1.
If the valve 8 is utilized in the suction line, a tapered tubular extension 15 providing entrance to the valve and integral with the valve housing is pressed into the tube 12 to mount the valve. At the top thereof, the valve housing is provided with a lateral tube 16 forming an exit opening. If the valve is utilized, a fitting 17 shown in FIG. 4 which is in the form of a tube narrowing externally away from a central cylindrical portion 18, is inserted in one end of the part 16 of the valve and the vacuum tube 3 is pressed over the other end of the fitting.
At the outset, when the receiver is shipped, the upper and lower sections 9 and 10 are nested one within the other as seen in FIG. 6 to save shipping space as well as storage. If so desired, a number of sections for a plurality of receivers may be nested in one stack. A thin sheet of plastic may be used between nested sections in order to facilitate easy removal thereof.
Each of the upper and lower sections 9 and 10 is provided with an annular interlocking arrangement complemental to that of the other section for interlocking engagement. These interlocking arrangements are provided around the large open ends of the sections. In the illustrated instance, the upper section 9 is provided with an annular interlocking arrangement, generally indicated by numeral 19, on the external margin of its open end. The lower section 10 is provided with an annular cylindrical portion at its open end, with an interlocking arrangement, generally indicated by numeral 21, inside that cylindrical portion. These interlocking arrangements could be reversed, that is exchanged one to the other section, if so desired.
With reference more particularly to FIG. 7, it will be seen that the taper of the upper section 9 allows its entry into the cylindrical portion 20 of the lower section. The taper of the arrangement 19 terminates exteriorly at the point 22 to slightly overlap the upper edge of the cylindrical portion 20 of the lower section. Then the upper section is preferably straight as at 23 for intimate face-to-face engagement with the upper portion 20 on the lower section. This straight portion on the upper section includes an outstanding annular detent 24 which functions like a hook and seats in a complemental recess 25 in the portion 20, the top of the detent 24 being flat to abut a flat shoulder at the top of the recess, as indicated at 26. The lower end of the part 19 is chamfered in the inside as indicated at 27 to form a narrow projection 28 to seat in a groove 29 formed in the part 20 of the lower section. Therefore, when the sections are united, there is a point of seal at 22, a positive seal at 26, and a seal in the groove 29.
While the sections 9 and 10 are molded with sufficient rigidity to be self-sustaining, there is enough resiliency to permit the upper portion 9 to be snapped at its open end into the cylindrical portion 20 of the lower section 10. Consequently, when the device is put to use, it is a simple expedient to separate the nested sections, invert the upper section, and snap the two sections together forming a positive fluid and airtight seal therebetween, which cannot be separated except by breakage. The connections to the patient and vacuum line are then made and the receiver 1 put to use.
When drainage of the particular patient is completed, the receiver 1 may be disposed of with the drainage contents therein by means consistent with local hospital practice. If it is to be disposed of asceptically, it is a simple expedient to remove the connections to the vacuum line, and connect all or a portion of the patient line to the fitting 17. If the valve is contaminated, it remains in place and is disposed of with the receiver 1 as illustrated in FIG. 3. However, if the valve is not contaminated, it should not be disposed of, but the fitting 17 can be removed and pressed in to the tube 12 and for asceptic disposal a portion or all of the patient's tube may be connected to the protruding part of the fitting. If so desired, the receptacle may be emptied through the patient tube 11 and discarded with other dry refuse. In cases where prolonged suction is required by a particular patient, the receptacle can be disconnected, the contents emptied and the receptacle returned for reuse by that same patient. Consequently, the receptacle meets the requirements or practice of substantially any hospital or similar institution.
The sections of the receptacle are preferably provided with indicating indicia 30 as seen in FIG. 2 and the sections are preferably transparent.
If a great amount of drainage is expected from a patient and several connections are not advisable, a central section may be added to the receptacle, as seen in FIGS. 8 and 9. The central section is provided at the bottom with the interlocking arrangement 19 like the upper section 9, and at the top with a cylindrical portion 20 and interlocking arrangement 21, the same as the lower section 10. While this intermediate section 31 is also transparent and is provided with indicia 32, compensation must be made for the amount in the intermediate section in addition to the amount shown on the upper and lower sections 9 and 10. Accordingly, the invention is extremely versatile in its usage. | A self-sustaining rigid body drainage collector including two or more sections each equipped with means for interlocking with another section when snapped together to provide a fluid tight joint; one of said sections having fittings for connection to the patient and to a vacuum line. The collector may be disposed of, empty or full, in an asceptic manner or emptied and reused on the same patient. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to devices that sense the exercise of muscles and, more particularly, to devices that sense and signal the performance of craniofacial and cervical muscle-toning exercises.
The value of physical exercise has received increased recognition in recent years. This recognition of the value of such exercise includes the recognition of the value of craniofacial and cervical muscle exercises, referred to generally hereafter as facial exercises. It is believed that facial exercise contributes to the toning of facial muscles with the result that people feel and look more alert, healthy, and vital. Such toning of the muscles is reported to give the face a firm look of alert, youthful energy.
In particular, in regard to the value of facial exercise, one can refer to the book Youth Lift by M. J. Saffon and Constance Schnader, 1981, Warner Books, Inc., 75 Rockefeller Plaza, New York, N.Y. 10019. The authors describe how to firm the neck, chin, and shoulders with minutes-a-day exercises. The exercises are recommended both in lieu of a face lift or in conjunction with a face lift.
One exercise recommended by such book to firm the entire mouth area and beautify the mouth is to form the lips into an extreme pointed pout. The lips are to be pushed out as far as possible to stretch and smooth the smiling grooves and lines that extend between the nose and the corners of the mouth. The upper lip is to be curled upward and the lower lip downward and the position held for a period of time, relaxed and repeated. To smooth and firm the cheeks and jaw line, the authors recommend pressing the lips and moving the mouth and jaw as far to one side as possible. The cheek is to be sucked against the teeth on the opposing side while the position is held for a period, relaxed and repeated. To firm sagging cheeks, the lips are to be pushed forward and formed in a slight pucker such that the syllable "O" can be pronounced. In this position, the lips are to be moved from one side of the face as far as possible. To tighten flabby skin and erase wrinkles in front of the ears, one is to yawn as far as open as possible and then slowly close the mouth, while fighting against letting the teeth meet. Each of the above exercises is illustrated in the book with a picture of the face when the exercise is properly performed.
It is customary to prescribe practicing facial exercises, such as the above, in front of a mirror. The mirror provides visual feedback as to whether the exercise is being performed in accordance with illustrative pictures. One drawback to this customary practice, and a drawback that provides a disincentive to perform the daily facial exercises is the physical restriction of maintaining prolonged visual contact with a mirror. The muscle exercise sensor device of the present invention overcomes this drawback. It allows one the physical freedom to move about, and even to perform other chores, while at the same time to receive feedback that one is performing the desired facial exercises. Feedback as to whether the desired exercise is being performed comes in the way of an audible, visual, or tactile signal.
The present invention also has application with those whose facial muscles have been impaired by injury or illness. The invention will aide the doctor to encourage exercise of those facial muscles which have been injured or diseased. For the patient, it will register immediate indications of success and progress. In this case, the function of the sensor might be to detect any movement at all of the facial muscles, not necessarily specific facial exercises. When the term "facial exercises" is used herein, the word exercise should be understood to refer not only to ordinary exercises but also, in some cases, simple movement.
SUMMARY OF THE INVENTION
The present invention comprises a sensor device to be worn by a subject that includes an attachment means to enable locating at least one sensing trigger in the vicinity of portions of facial muscle groups that the subject wearer desires to exercise. The sensing trigger communicates with a signal emitter that may, but need not, be located with the trigger. The trigger can detect motion of the appropriate muscles in at least one direction, which motion indicates that a desired facial exercise is being performed. Detecting the motion, the trigger activates the signal emitter that is powered to emit a signal to let the wearer know that the exercise is being performed. Preferably, the signal is audible, for its aesthetic value. A tactile or visual signal would also perform the function.
The attachment means may be adjustable to the subject's face and head. Further, the trigger location on the attachment means is preferably adjustable. Multiple triggers may be employed, connected either to one or to multiple signal senders and/or powering means. The powering means is preferably a 1.5 volt battery.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a side view of one sensor element attached to attachment means upon the head.
FIG. 2 shows a frontal view of one sensor element attached to attachment means upon the head.
FIG. 3 shows a frontal view of multiple sensor element attached to attachment means upon the head.
FIG. 4 shows a side view of multiple sensor element attached to attachment means upon the head.
FIG. 5 shows the muscular construction underlying the skin of the face and neck.
FIG. 6 is a schematic of one embodiment of a sensor element.
FIG. 7 illustrates the trigger of the above sensor element.
FIGS. 8 and 9 illustrate further the trigger for the above sensor element in its open and closed positions, respectively.
FIGS. 10 and 11 illustrate the device where the trigger is located separately from the signal sender and the power means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 illustrate an embodiment of the sensory device of the present invention that includes one sensor element 12 located upon attachment means 10 affixed to a subject's head. FIGS. 3 and 4 illustrate how the sensory device may be comprised of multiple sensor elements 12 located along attachment means 10. Each sensor element 12 in these figures comprises a trigger, a signal means, and a power means.
The attachment means 10 may be comprised of a flexible semi-rigid plastic that can be bent to the shape of the user's head and face. One material suitable for the attachment means is hollow ridged PVC 1/4" with 1/2" inside measurement. The attachment means may further include a cross piece 16 that fits over the forehead and adjustable ear pieces 14, as illustrated in FIGS. 3 and 4. Whereas, the attachment means of the preferred embodiment is comprised of flexible material that may be shaped to roughly conform to the user's head and face, it should be understood that the device also functions when a sensor element is attached to the skin by such attachment means as tape.
If the attachment means is roughly fixed with respect to the head and face, then preferably sensor elements 12, or at least the trigger T, can be adjusted in its location along the attachment means. The proper location of the sensor elements or trigger with respect to the face is a function of the muscles, as illustrated in FIG. 5, that the user wishes to exercise, as well as a function of the type of trigger utilized.
FIG. 6 illustrates one embodiment of a sensor element 12. This sensor element 12 is comprised of a housing H in which is located a signal sender, a battery and a trigger. The signal sender includes signaling means S, attached by wires 30 and 32 to circuit system CB, which in turn is connected by conducting lines 34 and 36 to battery B. Battery B is a typical 1.5 V watch-type battery. Circuit system CB is shown overlaying trigger T. No claim is being made per se to the particular circuitry of the signal sender with circuit CB disclosed in the preferred embodiment. Such a combination of trigger, battery and signal sender can be purchased and is found in children's toys, greeting cards and novelty gifts. The device disclosed in the preferred embodiment was manufactured by CALFAX.
It should be remembered that only trigger T needs to be located on the attachment means at location 12a, which is specifically located with respect to the muscles to be exercised. Battery B, circuit system CB and signalling means S can be located elsewhere in communication with trigger T, such as at location 50 toward the top of the head on attachment means 10. This is illustrated in FIGS. 10 and 11. Multiple triggers can communicate with one signal sending means. In FIGS. 10 and 11, location 50 contains the signal sending means S and the power means B. Location(s) 12a contains the trigger(s) T. Communication between S/B and T is by lines 52.
FIGS. 7, 8, and 9 further illustrate the interaction of circuit system CB with trigger T in housing H in the embodiment where S, B, CB, and T are all located in one sensor element. Trigger T is comprised of small solid metal cylinder 26 attached to the end of a metal strip 24 that is connected to base 28 located in the base of housing H. With no downward pressure on cylinder 26 (illustrated in FIG. 9) strip 24 flexes away from base 28 and touches contact 22, lying above flexible metal strip 24 in circuit system CB. Contact 22 is attached to circuit system CB upon the upper surface of housing H. A bore is created in housing H to permit cylinder 26 to flex on band 24 between a raised position, shown in FIG. 9, and a lowered position, shown in FIG. 8. In the raised position, strip 24 touches contact 22 of the circuit system CB and closes the circuit of the sensor S. In the lowered position, metal strip 24 does not touch contact 22, creating an "open circuit." Base 24 is connected to the circuitry of the sensor by conducting line 38. When metal strip 24 is touching contact 22, the circuit is closed between the conducting line 38 and the circuit system CB. When metal strip 24 is not touching contact 22, the circuit between conducting line 38 and circuit system CB containing conductor 22 is broken.
In operation, the attachment band 10 is fitted securely to the head and sensor element 12 is located with respect to a group of muscles that it is desired to exercise. In the preferred embodiment, illustrated sensor element 12 is located on the attachment band between the band and the face and touching the face such that pressure between the skin and the attachment means pushes cylinder 26 of trigger T into housing H toward base 28 and away from contact 22 on circuit system CB, thereby opening the circuit.
When a proper exercise of the facial muscle around sensor element 12 is effected, the muscle is stretched, depressing the plane of the face under sensor element 12 and permitting cylinder 26 of trigger T to move away from base 28 and into contact 22 on circuit system CB. The circuit then becomes closed. Power from battery B reaches signaling means S through circuit system CB. Musical bars are played, as dictated by circuit system CB, and detected by the wearer.
Having described the invention above, various modifications of the techniques, procedures, material, and equipment will be apparent to those in the art. It is intended that all such variations within the scope and spirit of the appended claims be embraced thereby. | A sensor device to detect and signal the exercise or movement of a subject's craniofacial and cervical muscles that includes a trigger attached to the subject, sensitive to movement in at least one direction and communicating with a signal emitter in order to emit an appropriate signal upon the sensing of movement that indicates the performance of the exercise. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a method of reactivating a used titania catalyst for hydrogenation treatment for reactivating a titania catalyst for hydrogenation treatment after use, exhibiting reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil, and to a regenerated titania catalyst for hydrogenation treatment, which is reactivated by the method.
BACKGROUND ART
[0002] When fossil fuels such as petroleum or coal are combusted, sulfur oxides (SOx), nitrogen oxides (NOx), and particulates such as sulfates, soot (carbon; graphite), or soluble organic fractions (SOF) derived from a sulfur content in the fossil fuel are generated and emitted to the atmosphere together with an exhaust gas. For example, the sulfur oxides have significant adverse effects on the global environment, such as causing acid rain or the like, destroying a nature environment such as a forest or a lake, and having a large impact on the ecosystem.
[0003] In such circumstances, for example in the automobile industry, technologies for exhaust gas control have been vigorously developed, such as a combination of high-pressure injection and exhaust gas recirculation (EGR), homogeneous charge intelligent multiple injection, a novel NOx catalyst. In addition, in the petroleum refining industry, there is a need to further reduce a concentration of the sulfur content in gasoline or gas oil with a view to applying the EGR effective for reducing NOx and reducing an impact on an after-treatment apparatus for removing the particulates.
[0004] From such viewpoints, a regulation particularly on the sulfur content in a petroleum fraction (hydrocarbon oil) such as gasoline, kerosene or gas oil, or heavy oil has been tightened, and a catalyst for hydrogenation treatment having excellent desulfurization activity enabling more efficient removal of the sulfur content in a hydrocarbon oil has been developed.
[0005] As a catalyst for hydrogenation treatment industrially currently used for removing sulfur in apetroleum fraction, a catalyst obtained by supporting a periodic table group VI metal such as molybdenum and tungsten and a periodic table group VIII to X metal such as cobalt and nickel on a porous alumina support is typical. As a catalyst having additionally excellent desulfurization activity, a hydrodesulfurization catalyst using a porous titania support has been known.
[0006] However, in fact, such catalyst is hardly industrially used as the catalyst for hydrogenation treatment for the purpose of removing the sulfur content in a hydrocarbon oil, so-called desulfurization, because titania has shortcomings such as a small specific surface area, poor formability, and low mechanical strength as compared to alumina, and further, is economically disadvantageous owing to its higher raw material cost as compared to alumina.
[0007] In view of the foregoing, various studies have hitherto been made for overcoming such shortcomings of the titania support.
[0008] For example, in Patent Literature 1, there is obtained a high-performance hydrodesulfurization catalyst having excellent thermal stability, a large specific surface area, high dispersion of a catalyst metal, improved catalytic activity, and high mechanical strength, by adding as a particle growth inhibitor an anion and a cation to a hydrosol or hydrogel of a hydrous oxide of titanium produced by a pH swing method, or a dried substance thereof, followed by drying and calcination.
[0009] In addition, for the purpose of obtaining a catalyst excellent in economic efficiency as well as desulfurization activity and mechanical strength, there has been made an attempt to make a composite of alumina having a low raw material cost and titania promising high performance. In Patent Literature 2, there is proposed a technology of a method of producing a catalyst support for hydrorefining treatment, involving co-precipitating an aluminum ion and a titanium ion to make a composite. In addition, in Patent Literature 3, there is proposed a method of producing an alumina-titania composite catalyst support, involving adding a titanium hydroxycarboxylate and/or a sol of titanium oxide or titanium hydroxide and a hydroxycarboxylic acid to aluminum oxide and/or aluminum hydroxide, followed by mixing and kneading, and calcination. Further, in Patent Literature 4, there is proposed a method of apparently converting a pore surface of an alumina support to titania, involving introducing a titanium tetrachloride gas to the alumina support to perform chemical vapor deposition of titanium on a surface of alumina. Further, in Patent Literature 5, there is proposed a technology of coating a pore surface of alumina with titanium, involving impregnating an alumina support with a solution containing titanium, followed by drying.
[0010] Further, for example in Non Patent Literature 1, there is disclosed a method of obtaining a titania-alumina support, involving precipitating (coating) titanium hydroxide on a surface of alumina hydrate particles, followed by aging, filtration, washing, forming, and calcination. In addition, the inventors of the present invention have proposed a catalyst production technology capable of producing a catalyst having a large specific surface area and high mechanical strength, and exhibiting activity as the hydrodesulfurization catalyst comparable to that of the hydrodesulfurization titania catalyst, even when 13 mass % or more of titanium oxide is supported, involving supporting titanium oxide on a surface of an inorganic oxide through precipitation and lamination of titanium oxide between an isoelectric point of the inorganic oxide and an isoelectric point of the titanium oxide, to chemically and macroscopically integrate the inorganic oxide and the titanium oxide (Patent Literature 6).
[0011] Further, in Patent Literature 7, there is disclosed a method of producing a catalyst for hydrogenation treatment, involving impregnating an alumina support with a catalyst component-containing aqueous solution containing a catalyst metal, phosphoric acid, and an additive selected from a dihydric or trihydric alcohol having 2 to 10 carbon atoms in one molecule, an ether thereof, a monosaccharide, a disaccharide, and a polysaccharide, followed by drying at 200° C. or less. In addition, in Patent Literature 8, there is proposed a method involving adding a water-soluble organic compound having a molecular weight of 100 or more and having a hydroxyl group and/or an ether bond, such as a diol, an alcohol, an ether group-containing water-soluble polymer, a saccharide, and a polysaccharide, to a catalyst component-containing aqueous solution, in production of a catalyst for hydrogenation treatment by supporting a catalyst metal on a support obtained by supporting an aqueous solution containing a titanium compound on an alumina hydrogel and then performing calcination. Further, the inventors have proposed a method of obtaining a titania catalyst for hydrogenation treatment, involving coating a surface of alumina hydrate particles with titanium hydroxide particles, followed by forming and then drying, and impregnating an obtained titania-coated alumina support with a catalyst component-containing aqueous solution containing a catalyst metal compound and a saccharide, followed by drying (Patent Literature 9).
[0012] Although those titania catalysts for hydrogenation treatment using titania supports exploit excellent features of a titania support and overcome the shortcomings to some extent, the problem of being particularly economically disadvantageous from an industrial viewpoint has not yet been overcome.
[0013] Meanwhile, for the catalyst for hydrogenation treatment, there has been made an attempt to reactivate a used catalyst that has been used for hydrogenation treatment of a hydrocarbon oil and thus has reduced catalytic activity and utilize the catalyst as a regenerated catalyst.
[0014] For example, in association with a catalyst for hydrogenation treatment obtained by supporting a catalyst metal on an inorganic oxide support containing alumina and titania, there is disclosed, in Patent Literature 10, using, in a second desulfurization step, a regenerated catalyst regenerated through a precipitated coke removal reaction under the conditions of an air partial pressure of from 0.05 to 5 MPa and a temperature of from 200 to 800° C., in the case of conducting hydrogenation treatment of gas oil by two steps of a first desulfurization step and the second desulfurization step. In addition, in association with the above-mentioned catalyst for hydrogenation treatment, there is disclosed, in Patent Literature 11, regenerating a used catalyst through calcination treatment at 300° C. for 1 hour in a nitrogen atmosphere, followed by calcination treatment at 450° C. for 3 hours in a mixed gas atmosphere of 50% nitrogen gas and 50% air.
[0015] Further, in association with a catalyst for hydrogenation treatment obtained by supporting a catalyst metal such as molybdenum, cobalt, nickel, and phosphorus on an alumina support containing in the catalyst an organic additive such as diethylene glycol, citric acid, and polyethylene glycol, there is disclosed, in Patent Literature 12, performing stripping treatment at from 100 to 370° C. in the presence of an oxygen-containing gas, and then, performing regeneration treatment at from 300 to 500° C. in the presence of an oxygen-containing gas. In addition, in association with the above-mentioned catalyst for hydrogenation treatment, there is disclosed, in Patent Literature 13, activating a used catalyst through regeneration treatment at from 300 to 650° C. in the presence of an oxygen-containing gas after stripping treatment of hydrocarbon, followed by impregnation with “a solution containing an acid and an organic additive” such as: citric acid and polyethylene glycol; or phosphoric acid and polyethylene glycol, and then drying.
CITATION LIST
Patent Literature
[0000]
[PTL 1] JP 2002-028485 A
[PTL 2] JP 05-096161 A
[PTL 3] JP 05-184921 A
[PTL 4] JP 06-106061 A
[PTL 5] JP 2001-276626 A
[PTL 6] JP 2004-033819 A
[PTL 7] JP 06-226108 A
[PTL 8] JP 2002-085975 A
[PTL 9] JP 2011-206695 A
[PTL 10] WO 01/015805 A1
[PTL 11] JP 2006-061845 A
[PTL 12] JP 4748497 B2
[PTL 13] JP 2007-507334 A
Non Patent Literature
[0000]
[NPL 1] Mat. Res. Soc. Symp. Proc. Vol. 346 445-450 1994
SUMMARY OF INVENTION
Technical Problem
[0030] In view of the forgoing, the inventors of the present invention have made extensive studies on reactivating a used titania catalyst for hydrogenation treatment exhibiting reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil to improve its catalytic activity to a level comparable to that of a fresh titania catalyst before use and using the catalyst as a regenerated titania catalyst for hydrogenation treatment.
[0031] The inventors of the present invention have tried regenerating the titania catalyst for hydrogenation treatment after use through coke removal treatment for removing a carbonaceous component on the surface of the catalyst by heating the catalyst at 500° C. in an oxygen-containing gas atmosphere, but this results in the finding that the catalytic activity (desulfurization activity) of the obtained regenerated titania catalyst is still less than 60% of that of a newly prepared fresh titania catalyst and it is difficult to reactivate the catalyst to the extent that the catalyst can be reused only through the coke removal treatment.
[0032] In such circumstances, the inventors have further tried reactivating the regenerated titania catalyst after the coke removal treatment through impregnation with the “solution containing an acid and an organic additive,” followed by drying, in conformity to the activation method disclosed in Patent Literature 13 (Comparative Example 2 described later). However, also in this case, the catalytic activity (desulfurization activity) of the obtained regenerated titania catalyst is still less than 65% of that of a fresh titania catalyst before use, and it is difficult to reactivate the catalyst to the extent that the catalyst can be reused. The cause of such result is not clearly revealed, but the inventors consider the cause as described below.
[0033] The titania support and the alumina support seem to have the following difference. Specifically, in the case of alumina, its zeta potential hardly changes in a weakly acidic region of from pH 3 to 7. Therefore, in the case of an alumina catalyst, the interaction between the support and molybdenum serving as a catalyst metal is not affected even when a weak acid is added as an activation substance for regeneration. In contrast, in the case of titania, its zeta potential changes drastically from a minus side to a plus side in such pH region. Therefore, in the case of a titania catalyst, the interaction between the support and anionic molybdenum oxide is likely to be increased when an acid is added. It is pointed out that molybdenum exhibiting a strong interaction with a support is generally hardly sulfurized, and hence has low desulfurization reactivity. Accordingly, it seems that, when an acid is added to the titania catalyst as an activation substance for regeneration, the desulfurization activity is affected, and hence an effect of reactivating the catalyst is not obtained.
[0034] In this context, the inventors have made further studies on reactivating the titania catalyst for hydrogenation treatment after use. As a result, the inventors have found a surprising fact that the catalytic activity (desulfurization activity) of the regenerated titania catalyst can be improved to a level comparable to that of a newly prepared fresh titania catalyst by impregnating a carbonaceous component-removed catalyst obtained through the coke removal treatment with a saccharide-containing solution containing a saccharide, and drying the obtained saccharide-impregnated catalyst, to allow the saccharide to be supported. Thus, the present invention has been completed.
[0035] Accordingly, an object of the present invention is to provide a method of reactivating a used titania catalyst for hydrogenation treatment, capable of improving the catalytic activity of the used titania catalyst for hydrogenation treatment that is obtained by supporting a catalyst component on a titania support and exhibits reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil, to a level comparable to that of a newly prepared fresh titania catalyst before use.
[0036] In addition, another object of the present invention is to provide a regenerated titania catalyst for hydrogenation treatment, which is regenerated by the method of reactivating a used titania catalyst for hydrogenation treatment and exhibits catalytic activity comparable to that of a fresh titania catalyst before use.
Solution to Problem
[0037] That is, according to one embodiment of the present invention, there is provided a method of reactivating a used titania catalyst for hydrogenation treatment, the used titania catalyst for hydrogenation treatment being obtained by supporting a catalyst component on a titania support and exhibiting reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil, the method including: a coke removal step of removing a carbonaceous component on a surface of the used catalyst by heating the catalyst in an oxygen-containing gas atmosphere; an impregnation step of impregnating the carbonaceous component-removed catalyst obtained by the coke removal step with a saccharide-containing solution; and a drying step of drying the saccharide-impregnated catalyst obtained by the impregnation step to obtain a catalyst in which a saccharide is supported.
[0038] According to another embodiment of the present invention, there is provided a regenerated titania catalyst for hydrogenation treatment, which is obtained by the method of reactivating a used titania catalyst for hydrogenation treatment described above.
[0039] In the present invention, the catalyst for hydrogenation treatment to be reactivated is a titania catalyst for hydrogenation treatment after use that is obtained by supporting a catalyst component on a titania support and exhibits reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil.
[0040] Herein, as the titania support, a titania support having a large specific surface area and high thermal stability as compared to the related-art titania is preferred. For example, there may be given any known titania supports such as the titania disclosed in Patent Literature 1. From the viewpoints of catalyst strength and catalyst production cost, more preferred are the titania-coated alumina supports including a titania coating layer on the surface of alumina disclosed in Patent Literatures 4, 6, and 9, not just a mixture of alumina and titania.
[0041] In addition, the catalyst component to be supported on the titania support generally includes at least one kind of periodic table group VI metal compound, at least one kind of periodic table group VIII to X metal compound, and at least one kind of phosphorus compound. Herein, as preferred periodic table group VI metals, there are given molybdenum and tungsten. In particular, molybdenum is preferred. In addition, as preferred molybdenum compounds, there are given molybdenum trioxide, molybdic acid, ammonium molybdophosphate, and ammonium paramolybdate. In addition, as periodic table group VIII to X metals, there are given cobalt and nickel. As preferred nickel compounds, there are given, for example, nickel nitrate, nickel sulfate, nickel acetate, nickel carbonate, nickel chloride, nickel hydroxide, and basic nickel carbonate. In addition, as preferred cobalt compounds, there are given, for example, cobalt nitrate, cobalt sulfate, cobalt acetate, basic cobalt carbonate, cobalt carbonate, cobalt chloride, and cobalt hydroxide. Any one kind of those cobalt compounds and nickel compounds may be used alone, or two or more kinds thereof may be used in combination. Further, preferred examples of the phosphorus compound include phosphorus pentaoxide, diammonium hydrogen phosphate, ammonium dihydrogen phosphate, disodium hydrogen phosphate, sodium dihydrogen phosphate, and orthophosphoric acid.
[0042] In the present invention, the newly prepared fresh titania catalyst for hydrogenation treatment before use may be a catalyst obtained by impregnating the titania support with a catalyst component-containing solution containing, in addition to the catalyst component, any organic additive heretofore known contributing to catalytic activity, and then performing drying. Examples of the organic additive to be used for this purpose include organic acids, aliphatic dialcohols, ethers and polyethers, saccharides, and nitrogen-containing compounds.
[0043] In the present invention, the titania catalyst after use exhibiting reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil refers to a used titania catalyst for hydrogenation treatment that has been used for hydrogenation treatment (desulfurization treatment) of an petroleum oil fraction (hydrocarbon oil) such as gasoline, a kerosene or gas oil, or a heavy oil particularly for the purpose of removing a sulfur content contained therein, has catalytic activity reduced to about 60%, or less of initial catalytic activity owing to deposition of a carbonaceous component on the catalyst with use, and hence cannot achieve a target sulfur content concentration after the hydrogenation treatment (for example, 10 ppm or less in the case of gas oil), and is recovered from the hydrogenation treatment step.
[0044] [Coke Removal Step]
[0045] In the present invention, the reactivation of the used titania catalyst for hydrogenation treatment begins with the coke removal step of removing a carbonaceous component, which is present on the surface of the used catalyst and causes a reduction in the catalytic activity, through combustion, by heating the catalyst at a temperature of 350° C. or more and 600° C. or less, preferably 400° C. or more and 550° C. or less in an oxygen-containing gas atmosphere. In general, it is appropriate to perform calcination treatment under the conditions that the content of the carbonaceous component becomes 3 wt % or less, preferably 2 wt % or less. As the oxygen-containing gas to be used in this step, any gas may be used as long as the gas contains oxygen and allows for the removal of the carbonaceous component on the surface of the used catalyst through combustion. In general, air, an oxygen-containing nitrogen gas, or the like is used. In addition, while the heating temperature varies depending on the kind of the titania support to be used, the following problems may arise: when the heating temperature is less than 350° C., it becomes difficult to completely remove the carbonaceous component on the surface of the used catalyst through combustion; and in contrast, when the heating temperature exceeds 600° C., alternation of the support or aggregation of the catalyst metal to be supported occurs.
[0046] [Impregnation Step]
[0047] The carbonaceous component-removed catalyst obtained by the coke removal step is then subjected to the impregnation step of impregnating the catalyst with a saccharide-containing solution. A saccharide to be used for this purpose is not particularly limited. Examples thereof include: trioses (glyceraldehyde, dihydroxyacetone, and glycerin), tetroses (such as erythrose, threose, erythrulose, and erythritol), pentoses (such as ribulose, xylulose, ribose, arabinose, xylose, xylitol, lyxose, and deoxyribose), hexoses (suchaspsicose, fructose, sorbose, tagatose, allose, altrose, glucose, mannose, gulose, idose, galactose, talose, fucose, fuculose, rhamnose, sorbitol, mannitol, dulcitol, or galactitol, glucosamine, galactosamine, inositol, and invert sugar), and heptoses (such as sedoheptulose) as monosaccharides; sucrose, lactose, maltose, trehalose, maltitol, turanose, cellobiose, gentiobiose, isomaltose, kojibiose, laminaribiose, melibiose, nigerose, and sophorose as disaccharides; raffinose, melezitose, and maltotriose as trisaccharides; acarbose and stachyose as tetrasaccharides; fructooligosaccharide, galactooligosaccharide, and mannanoligosaccharide as oligosaccharides; glycogen, starch, cellulose, dextrin, glucan, fructan, guar gum, and N-acetylglucosamine as polysaccharides; and isomerized sugar.
[0048] From the viewpoint of economic efficiency, it is preferred that the saccharide-containing solution to be used in the impregnating step be a solution such as a water or alcohol solution containing one kind or two or more kinds of saccharides selected from the group consisting of glucose, fructose, erythritol, xylose, xylitol, sorbitol, mannitol, invert sugar, maltose, trehalose, maltitol, isomerized sugar, and raffinose.
[0049] In addition, the saccharide concentration in the saccharide-containing solution to be used in the impregnation step is not particularly limited, but needs to be adjusted to a concentration range suitable for the saccharide for the following reasons: when the saccharide concentration is too low, the catalyst cannot be impregnated with a predetermined amount of the saccharide because the catalyst can be impregnated with the solution in an amount just commensurate with the pore volume of the support; and in contrast, when the saccharide concentration is too high, the viscosity of the solution is increased and the solution cannot penetrate the pores of the catalyst sufficiently. The saccharide concentration is generally 5 mass % or more and 60 mass % or less, preferably 10 mass % or more and 50 mass % or less. When the saccharide concentration is less than 2 mass %, there arises a problem in that the catalyst cannot be impregnated with a predetermined amount of the saccharide, and in contrast, when the saccharide concentration exceeds 60 mass %, there may arise a problem of incomplete dissolution of the saccharide.
[0050] Further, the usage amount of the saccharide, with which the carbonaceous component-removed catalyst is to be impregnated in the impregnation step through use of the saccharide-containing solution and which is to be supported on the carbonaceous component-removed catalyst through drying in the subsequent drying step, is generally 2 parts by mass or more and 30 parts by mass or less, preferably 5 parts by mass or more and 25 parts by mass or less, with respect to 100 parts by mass of the carbonaceous component-removed catalyst. When the usage amount of the saccharide is less than 2 parts by mass, an effect obtained by adding the saccharide is not remarkably exhibited, and in contrast, when the saccharide is added in excess of 30 parts by mass, an effect obtained by adding the saccharide is not further increased.
[0051] In the impregnation step, the carbonaceous component-removed catalyst after impregnated with the saccharide-containing solution is allowed to stand still in that state for a predetermined time period to be aged as required with a view to uniformly and stably supporting the saccharide on the carbonaceous component-removed catalyst. The time period for aging is preferably set to a range of from 10 minutes to 24 hours.
[0052] In addition, in the impregnation step, the saccharide-containing solution may contain, in addition to the saccharide, a catalyst component including at least one kind of periodic table group VI metal compound, at least one kind of periodic table group VIII to X metal compound, and at least one kind of phosphorus compound, as required. The addition of such catalyst component compensates for a loss fraction of the catalyst component supported on the titania support of the titania catalyst for hydrogenation treatment before use, which is lost through its use and/or the coke removal treatment in its reactivation. With this, the regenerated titania catalyst for hydrogenation treatment after reactivation can certainly exhibit catalytic activity close to the catalytic activity of the titania catalyst for hydrogenation treatment before use.
[0053] In addition, the catalyst component to be added to the saccharide-containing solution is preferably the same catalyst component as the catalyst component supported on the titania support in the titania catalyst for hydrogenation treatment before use. That is, the catalyst component is preferably a catalyst component including at least one kind of periodic table group VI metal compound, at least one kind of periodic table group VIII to X metal compound, and at least one kind of phosphorus compound. The catalyst component more preferably includes the same respective compounds as the periodic table group VI metal compound, the periodic table group VIII to X metal compound, and the phosphorus compound used in the titania catalyst for hydrogenation treatment before use.
[0054] Further, the added amount of the catalyst component in the saccharide-containing solution may be any amount as long as the loss fraction of the catalyst component lost through use of the catalyst and/or the coke removal treatment in its reactivation can be compensated. The added amount is preferably such an amount that the total amount of the periodic table group VI metal compound, the periodic table group VIII to X metal compound, and the phosphorus compound in the catalyst component is 5 mass % or less with respect to the catalyst component of the regenerated titania catalyst for hydrogenation treatment after reactivation, in terms of an oxide, for the following reasons: the loss fraction of the catalyst component is empirically about 5 mass % or less; in addition, addition beyond necessity may disadvantageously reduce the catalytic activity owing to association between the original catalyst component and the added one; and further, from an economic viewpoint, the added amount is preferably as low as possible, as long as desired catalytic activity (for example, 70% of that of the titania catalyst for hydrogenation treatment before use) is obtained after the reactivation.
[0055] [Drying Step]
[0056] The saccharide-impregnated catalyst obtained in the impregnation step through impregnation with the saccharide-containing solution is then dried to allow the saccharide to be stably supported on the carbonaceous component-removed catalyst. Thus, the regenerated titania catalyst for hydrogenation treatment through activation is obtained. The drying conditions in the drying step are preferably as follows: a drying temperature falling within a range of 100° C. or more and 400° C. or less, preferably 110° C. or more and 300° C. or less; and a drying time period falling within a range of 0.5 hour or more and 24 hours or less, preferably 1 hour or more and 12 hours or less. While the drying temperature varies depending on the kind of the titania support to be used, it is easy to imagine that various problems occur during a reaction because of a remaining water content when the drying temperature is less than 100° C. In contrast, when the drying temperature exceeds 400° C., there arises a problem of carbonization of the saccharide.
[0057] The regenerated titania catalyst for hydrogenation treatment obtained by the method of the present invention exhibits catalytic activity (desulfurization activity) recovered to a level comparable to that of a new titania catalyst for hydrogenation treatment before use, specifically recovered to a value exceeding at least 70%, preferably exceeding 75%, given that the catalytic activity of a new titania catalyst for hydrogenation treatment before use is taken as 100. The regenerated titania catalyst for hydrogenation treatment can be used again for hydrogenation treatment generally as it is, while depending on the use purpose.
[0058] Now, a method of using the regenerated titania catalyst for hydrogenation treatment of the present invention is hereinafter described, taking as an example hydrogenation treatment, in particular desulfurization treatment, of a hydrocarbon oil.
[0059] When the regenerated titania catalyst for hydrogenation treatment of the present invention is used to perform desulfurization treatment, it is desired to first perform pre-sulfurization for activating the catalyst metal. The pre-sulfurization is performed by using as a pre-sulfiding agent hydrogen sulfide, carbon disulfide, thiophene, dimethyl disulfide, a hydrocarbon oil containing those compounds, or the like.
[0060] The desulfurization treatment is performed after the pre-desulfurization. The treatment conditions of the desulfurization treatment are generally preferably as follows: a reaction temperature falling within a range of from 250 to 450° C.; and a hydrogen partial pressure falling within a range of from 1 to 15 MPa, while the conditions vary depending on the kind of a raw material oil or the purpose.
[0061] In addition, the reaction mode of the desulfurization treatment is not particularly limited. Examples of the reaction mode include a fixed-bed mode, a movable-bed mode, an ebullating-bed mode, and a suspension-bed mode, and any of those modes may be adopted. The reaction conditions in the case of adopting the fixed-bed mode are preferably as follows: a liquid hourly space velocity (LHSV) falling within a range of from 0.1 to 5 hr −1 ; and a volume ratio of hydrogen/raw material oil falling within a range of from 50 to 500 Nm 3 /kl.
[0062] Specific examples of the hydrocarbon oil that can be treated by using the regenerated titania catalyst for hydrogenation treatment of the present invention include oils ranging from gasoline, a kerosene oil, a light gas oil, a heavy gas oil, and a light cycle oil to an atmospheric residual oil, a vacuum residual oil, an oil sand oil, and a tar sand oil.
Advantageous Effects of Invention
[0063] According to one embodiment of the present invention, it is possible to reactivate the used titania catalyst for hydrogenation treatment exhibiting reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil, to recover its catalytic activity to a level comparable to that of a fresh titania catalyst before use. Therefore, the obtained regenerated titania catalyst for hydrogenation treatment can be used almost equally to a fresh titania catalyst. Accordingly, the present invention is industrially extremely beneficial, because excellent features of a titania support are utilized and further the shortcoming of “being economically disadvantageous”, that is a major problem from an industrial viewpoint, can be overcome.
DESCRIPTION OF EMBODIMENTS
[0064] Embodiments of the present invention are hereinafter described in detail on the basis of Examples, Reference Examples, and Comparative Examples. It should be noted that various physical properties, catalyst performance, and the like were measured under the following procedures and conditions in Examples, Reference Examples, and Comparative Examples described below.
[0065] [Treatment Before Measurement]
[0066] Upon measurement of various physical properties, an object to be measured was preliminarily subjected to calcination treatment under the conditions of 500° C. and 3 hours, and then analyzed.
[0067] [Measurement of Pore Distribution and Pore Volume]
[0068] The pore distribution and pore volume of a catalyst or a support were measured by mercury porosimetry through pressurization up to a measurement pressure of 414 MPa using AutoPore IV9520 manufactured by SHIMADZU CORPORATION.
[0069] [Pore Sharpness Degree]
[0070] The “pore sharpness degree” is a numerical value that specifies the uniformity of a pore size. Herein, a pore sharpness degree closer to 100% means that the pore size of a catalyst or a support is more fully uniform. Specifically, a pore size corresponding to 50% cumulative pore volume (median size) is determined, and then, a partial pore volume (PVM) of ones in the pore size range of ±5% of the logarithmic value of the median size is determined. The pore sharpness degree is determined by the following equation based on the partial pore volume (PVM) and the pore volume (PVT). That is, the pore sharpness degree can be calculated by the following equation based on a cumulative pore distribution curve measured by mercury porosimetry.
[0000] Pore sharpness degree (%)=( PVM/PVT )×100
[0071] [Desulfurization Test of Gas Oil]
[0072] A hydrodesulfurization test of gas oil for measuring the desulfurization activity of a hydrogenation treatment catalyst was performed as described below.
[0073] The hydrodesulfurization test was performed by using a high-pressure fixed-bed flow reactor and loading 15 ml of a catalyst under the conditions of: reaction pressure: 5 MPa; reaction temperature: 340° C.; liquid hourly space velocity: 1.5 h −1 ; and volume ratio of hydrogen/raw material: 250 N1/1. All the catalysts for hydrogenation treatment subjected to the test were preliminarily subjected to sulfurization treatment (pre-sulfurization) using gas oil having a sulfur concentration adjusted to 2.5% (in terms of mass) through addition of dimethyl disulfide. Straight-run gas oil from the Middle East subjected to the hydrodesulfurization test has the following properties: specific gravity (15/4° C.): 0.849; sulfur content: 1.21 mass %; nitrogen content: 96 ppm; and initial distillation temperature of 228° C., 50% distillation temperature of 293° C., and 90% distillation temperature of 347° C., as distillation properties.
[0074] The desulfurization activity of the catalyst for hydrogenation treatment was determined as described below. The rate constant of a desulfurization reaction was determined on the assumption that the desulfurization reaction was a 1.2-order reaction, and an average value of the rate constants of the desulfurization reaction between a reaction time period of from 100 to 144 hours was calculated. Desulfurization activity relative to that of a catalyst for hydrogenation treatment of Reference Example 1 or Reference Example 2 described below was determined and represented as “relative desulfurization activity,” given that the average value of the rate constants of the desulfurization reaction in the case of a titania catalyst for hydrogenation treatment, HBT-1, in Reference Example 1 or an alumina catalyst for hydrogenation treatment, ALC-1, in Reference Example 2 was taken as 100.
[0075] [Preparation of Titania Catalyst for Hydrogenation Treatment]
<Preparation of Raw Material Solution>
[0076] The following solutions were each prepared in the full amount required for the operations described below: solution A obtained by adding 1,030 g of water with respect to 970 g of aluminum chloride hexahydrate; solution B obtained by adding 1,000 g of water with respect to 1,000 g of 28% ammonia water; solution C obtained by adding water to 198 g of a titanium tetrachloride solution having a Ti concentration of 16.6 mass % and a Cl concentration of 32.3 mass %, to give a volume of 1.8 liters (L); solution D obtained by adding water to 231 g of 14% ammonia water, to give a volume of 1.8 L; and solution E obtained by adding 733 g of hydrochloric acid and 13 g of water to 1,520 g of a titanium tetrachloride solution having a Ti concentration of 16.7 mass % and a Cl concentration of 32.6 mass %.
Reference Example 1
Production of Alumina Hydrate Particle
[0077] (a) 14 L of water were loaded in an enamel vessel of 19 L, and heated to 80° C. while being stirred. 850 g of the solution A were added to the enamel vessel and the mixture was maintained for 5 minutes. The solution at this time (hereinafter referred to as “synthetic solution”) had a pH of 2.5. Next, the solution B was added to the enamel vessel in such an amount that the pH of the synthetic solution became 7.5, and the mixture was maintained for 5 minutes (first pH swing).
[0078] (b) After that, 850 g of the solution A were added thereto to allow the pH of the synthetic solution to 3.0, and the mixture was maintained for 5 minutes. Then, the solution B was added thereto again in such an amount that the pH of the synthetic solution became 7.5, and the mixture was maintained for 5 minutes (second pH swing).
[0079] (c) Then, a chlorine ion and an ammonium ion as impurities were removed by washing. Thus, alumina hydrate particles subjected to pH swing twice were obtained.
[0080] <Production of Titania-Coated Alumina Support>
[0081] 122 g of the obtained alumina hydrate particles were collected in terms of an oxide, and well stirred with a mixer while water was added thereto, to provide 8 L of a dispersion. While the dispersion was maintained at 60° C., the solution C was added thereto to adjust the pH to 5.0. Then, the solution C and the solution D each in an amount of 1.8 L were added thereto simultaneously over about 2 hours so that the pH was continuously maintained within a range of 5.0±0.1. Thus, titania-coated alumina hydrate particles were produced. The coating amount of titania in the obtained titania-coated alumina hydrate particles is 31%.
[0082] An ammonia ion and a chlorine ion coexisting with the titania-coated alumina hydrate particles thus obtained were removed by washing with water. Filtration was performed to achieve a water content rate allowing for forming. The resultant was formed into a cylindrical shape having a diameter of 1.2 mm through extrusion molding (forming step), followed by drying at 120° C. for 16 hours and further calcination at 500° C. for 3 hours (first drying step). Thus, a titania-coated alumina support was obtained.
[0083] The obtained titania-coated alumina support was measured for the specific surface area and the pore distribution, and subjected to X-ray diffraction.
[0084] As a result, it was found that the specific surface area was 400 m 2 /g, the pore volume was 0.57 ml/g, and the pore sharpness degree was 76.5%. In addition, there was detected no titania in an anatase crystal form.
[0085] <Production of Titania Catalyst>
[0086] 34.5 g of molybdenum oxide, 7.7 g of cobalt carbonate in terms of CoO, and 5.0 g of 85% phosphoric acid were added to water, and dissolved through heating while being stirred. Thus, a catalyst component aqueous solution having a total weight adjusted to 100.0 g was obtained. Further, 4.3 g of sorbitol were dissolved in 27.6 g of the obtained catalyst component aqueous solution. Thus, an aqueous solution containing a catalyst component was obtained.
[0087] 30.0 g of the titania-coated alumina support obtained above were impregnated with the aqueous solution containing a catalyst component, followed by drying at 120° C. for 12 hours. Thus, a titania catalyst for hydrogenation treatment, HBT-1, was obtained.
[0088] It was found that the obtained titania catalyst for hydrogenation treatment had a specific surface area of 232 m 2 /g, a pore volume of 0.36 ml/g, and a pore sharpness degree of 70.2%.
[0089] A hydrodesulfurization test of gas oil using the obtained catalyst was performed under the reaction conditions described above. The average value of the rate constants of the desulfurization reaction was taken as 100, and used as a standard for evaluation of the catalytic activity (relative desulfurization activity) of regenerated titania catalysts for hydrogenation treatment (hereinafter referred to as “regenerated catalyst”) obtained in Examples 1 to 5 and Comparative Examples 1 to 3 described below.
[0090] [Regeneration of Used Titania Catalyst for Hydrogenation Treatment]
Example 1
[0091] The used titania catalyst for hydrogenation treatment HBT-1 recovered after operation in a hydrodesulfurization apparatus for gas oil for about 1 year was washed with a toluene solvent to remove an oil content. Then, the resultant was dried at 120° C. for 10 hours in an air atmosphere to remove the solvent. At this time, the catalyst contained 14.7 wt % of a carbon content and 8.5 wt % of a sulfur content.
[0092] The catalyst after the drying treatment was subjected to coke removal treatment (coke removal step) by rotating the catalyst in a rotary calcination furnace with keeping the furnace temperature at 350° C. for 3 hours and then gradually elevating the temperature and keeping the furnace temperature at 500° C. for 3 hours, while allowing a low oxygen concentration gas having an oxygen concentration of 2.0% obtained through dilution of air with nitrogen to flow into the furnace. It was found that the catalyst after the calcination treatment contained 0.87% of a carbon content and 0.62% of a sulfur content. The catalyst after the coke removal treatment was represented as RHBT-1.
[0093] 30 g of the catalyst RHBT-1 after the coke removal treatment were impregnated with sorbitol by using an aqueous solution containing 22.1 wt % of sorbitol so that the content of sorbitol was 10 wt % with respect to the catalyst. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RHBT-2 was obtained.
Example 2
[0094] 30 g of the catalyst RHBT-1 after the coke removal treatment were impregnated with sorbitol by using an aqueous solution containing 22.5 wt % of glucose so that the content of glucose was 10 wt % with respect to the catalyst. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RHBT-3 was obtained.
Example 3
[0095] 30 g of the catalyst RHBT-1 after the coke removal treatment were impregnated with sorbitol by using an aqueous solution containing 12.0 wt % of glucose so that the content of glucose was 5 wt % with respect to the catalyst. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RHBT-4 was obtained.
Example 4
[0096] 30 g of the catalyst RHBT-1 after the coke removal treatment were impregnated with sorbitol by using an aqueous solution containing 21.9 wt % of sucrose so that the content of sucrose was 10 wt % with respect to the catalyst. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RHBT-5 was obtained.
Example 5
[0097] 30 g of the catalyst RHBT-1 after the coke removal treatment were impregnated with sorbitol by using an aqueous solution containing 22.4 wt % of maltitol so that the content of maltitol was 10 wt % with respect to the catalyst. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RHBT-6 was obtained.
Example 6
[0098] 30 g of the catalyst RHBT-1 after the coke removal treatment were impregnated with sorbitol by using an aqueous solution containing 22.4 wt % of sorbitol, and as a catalyst component, 4.5 g of molybdenum oxide in terms of MoO 3 , 0.8 g of cobalt carbonate in terms of CoO, and 0.7 g of phosphoric acid in terms of P 2 O 5 so that the content of sorbitol was 10 wt % with respect to the catalyst. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RHBT-9 was obtained.
Comparative Example 1
[0099] The catalyst RHBT-1 after the coke removal treatment obtained in Example 1 was taken as a regenerated catalyst of Comparative Example 1.
Comparative Example 2
[0100] The catalyst RHBT-1 after the coke removal treatment was impregnated in the same manner as in Example 1 so that the content of citric acid was 5 wt % and the content of polyethylene glycol was 5 wt %. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RHBT-7 was obtained.
Comparative Example 3
[0101] The catalyst RHBT-1 after the coke removal treatment was impregnated in the same manner as in Example 1 so that the content of citric acid was 5 wt % and the content of glucose was 5 wt %. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RHBT-8 was obtained.
[0102] <Evaluation of Hydrodesulfurization Activity>
[0103] For measuring the desulfurization activities of the regenerated catalysts obtained in Examples 1 to 6 and Comparative Examples 1 to 3 as a catalyst for hydrogenation treatment, the hydrodesulfurization test of gas oil described in the above-mentioned [Desulfurization test of gas oil] section was performed. The relative desulfurization activities were summarized in Table 1.
Reference Example 2
[0104] An ammonia ion and a chlorine ion coexisting with the alumina hydrate particles obtained in the <Production of alumina hydrate particle> section in Reference Example 1 were removed by washing with water. Filtration was performed to achieve a water content rate allowing for forming. The resultant was formed into a cylindrical shape having a diameter of 1.2 mm through extrusion molding (forming step), followed by drying at 120° C. for 16 hours and further calcination at 500° C. for 3 hours (first drying step). Thus, an alumina support was obtained.
[0105] The obtained alumina support was measured for the specific surface area and the pore distribution, and subjected to X-ray diffraction. As a result, it was found that the specific surface area was 346 m 2 /g, the pore volume was 0.5 ml/g, and the pore sharpness degree was 65.9%.
[0106] <Production of Alumina Catalyst>
[0107] 34.5 g of molybdenum oxide, 7.7 g of cobalt carbonate in terms of CoO, and 5.0 g of 85% phosphoric acid were added to water, and dissolved through heating while being stirred. Thus, a catalyst component aqueous solution having a total weight adjusted to 100.0 g was obtained. Further, 4.3 g of sorbitol were dissolved in 27.6 g of the obtained catalyst component aqueous solution. Thus, an aqueous solution containing a catalyst component was obtained.
[0108] 30.0 g of the alumina support obtained above were impregnated with the aqueous solution containing a catalyst component, followed by drying at 120° C. for 12 hours. Thus, a titania catalyst for hydrogenation treatment, ALC-1, was obtained.
[0109] It was found that the obtained alumina catalyst for hydrogenation treatment had a specific surface area of 195 m 2 /g, a pore volume of 0.35 ml/g, and a pore sharpness degree of 62.4%.
[0110] A hydrodesulfurization test of gas oil using the obtained catalyst was performed under the reaction conditions described above. The average value of the rate constants of the desulfurization reaction was taken as 100, and used as a standard for evaluation of the catalytic activities (relative desulfurization activities) of regenerated catalysts obtained in Comparative Examples 4 to 6 described below.
[0111] [Regeneration of Used Alumina Catalyst for Hydrogenation Treatment]
Comparative Example 4
[0112] The used titania catalyst for hydrogenation treatment ALC-1 recovered after operation in a hydrodesulfurization apparatus for gas oil for about 1 year was washed with a toluene solvent to remove an oil content. Then, the resultant was dried at 120° C. for 10 hours in an air atmosphere to remove the solvent. At this time, the catalyst contained 16.7 wt % of a carbon content and 8.2 wt % of a sulfur content.
[0113] The catalyst after the drying treatment was subjected to regeneration treatment by rotating the catalyst in a rotary calcination furnace with keeping the furnace temperature at 350° C. for 3 hours and then gradually elevating the temperature and keeping the furnace temperature at 500° C. for 3 hours, while allowing a low oxygen concentration gas having an oxygen concentration of 2.0% obtained through dilution of air with nitrogen to flow into the furnace. It w-s found that the catalyst after the calcination treatment contained 0.77% of a carbon content and 0.54% of a sulfur content. The regenerated catalyst was represented as RALC-1.
Comparative Example 5
[0114] 30 g of the regenerated catalyst RALC-1 were impregnated with sorbitol by using an aqueous solution containing 22.1 wt % of sorbitol so that the content of sorbitol was 10 wt % with respect to the catalyst. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RALC-2 was obtained.
Comparative Example 6
[0115] 30 g of the regenerated catalyst RALC-1 were impregnated with sorbitol by using an aqueous solution containing 22.5 wt % of glucose so that the content of glucose was 10 wt % with respect to the catalyst. Then, the resultant was dried at 120° C. for 3 hours. Thus, a regenerated catalyst RALC-3 was obtained.
[0116] <Evaluation of Hydrodesulfurization Activity>
[0117] For measuring the desulfurization activities of the regenerated catalysts obtained in Comparative Examples 4 to 6 as a catalyst for hydrogenation treatment, the hydrodesulfurization test of gas oil described in the above-mentioned [Desulfurization test of gas oil] section was performed. The relative desulfurization activities were summarized in Table 2.
[0000]
TABLE 1
Additive in impregnation step
Saccharide or
Catalyst
organic
Catalyst
Relative
Kind of
No.
Acid
additive
component
activity
support
Reference
HBT-1
—
—
—
100
Titania-
Example 1
coated
Comparative
RHBT-1
None
None
—
52
Example 1
Example 1
RHBT-2
None
Sorbitol 10 wt %
—
91
Example 2
RHBT-3
None
Glucose 10 wt %
—
98
Example 3
RHBT-4
None
Glucose 5 wt %
—
77
Example 4
RHBT-5
None
Sucrose 10 wt %
—
88
Example 5
RHBT-6
None
Maltitol 10 wt %
—
93
Example 6
RHBT-9
None
Sorbitol 10 wt %
Mo, Co, P
98
Comparative
RHBT-7
Citric
Polyethylene
—
61
Example 2
acid 5 wt %
glycol 5 wt %
Comparative
RHBT-8
Citric
Glucose 5 wt %
—
64
Example 3
acid 5 wt %
[0000]
TABLE 2
Additive in
impregnation step
Catalyst
Saccharide or
Relative
Kind of
No.
Acid
organic additive
activity
support
Reference
ALC-1
—
—
100
Alumina
Example 2
Comparative
RALC-1
None
None
53
Example 4
Comparative
RALC-2
None
Sorbitol 10 wt %
62
Example 5
Comparative
RALC-3
None
Glucose 10 wt %
64
Example 6 | Provided is a method of reactivating a used titania catalyst for hydrogenation treatment, capable of improving the catalytic activity of the used titania catalyst for hydrogenation treatment that is obtained by supporting a catalyst component on a titania support and exhibits reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil, to a level comparable to that of a newly prepared fresh titania catalyst before use. The method of reactivating a used titania catalyst for hydrogenation treatment, the used titania catalyst for hydrogenation treatment being obtained by supporting a catalyst component on a titania support and exhibiting reduced catalytic activity after having been used for hydrogenation treatment of a hydrocarbon oil, includes: a coke removal step of removing a carbonaceous component on a surface of the used catalyst by heating the catalyst in an oxygen-containing gas atmosphere; an impregnation step of impregnating the carbonaceous component-removed catalyst obtained by the coke removal step with a saccharide-containing solution; and a drying step of drying the saccharide-impregnated catalyst obtained by the impregnation step, to obtain a catalyst in which a saccharide is supported. | 1 |
BACKGROUND OF THE INVENTION
The invention is based on a regulating device. In a known regulating device of this type the shaft must be loosened in the armature in order to adjust the center of rotation of the control element relative to the position of the annular slide and, after making the adjustment, must be re-fastened. This is not possible during operation, since the control element becomes inoperable once the shaft is loosened. However, it is desirable to have an accurate adjustment which can only be made during operation.
OBJECT AND SUMMARY OF THE INVENTION
The regulating device according to the present invention has the advantage that an adjustment can be made during operation, which therefore is very accurate, and that this adjustment is possible without changing the basic orientation of armature to magnet, etc. Three different possibilities are contained as embodiments of the invention.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of the preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 3 show the first exemplary embodiment;
FIGS. 4 to 6 the second exemplary embodiment; and
FIGS. 7 and 8 the third exemplary embodiment, in two variations, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all examples, a piston 1 is caused to move back and forth as well as to be rotated by a camshaft 2. The fuel, reaching a pump operation chamber 4 by means of an intake channel 3 during the intake stroke, is fed to the combustion engine by means of compression channels 5 during the compression stroke, until a relief channel 5 of the pump operation chamber 4 is opened by means of the annular slide 7, so that the remaining inflowing fuel is brought from the pump operation chamber 4 into a suction chamber 8 of the injection pump during this opening; the intake channel 3 also branches off from this suction chamber 8. The operational amount is therefore determined by the axial position of the annular slide 7. The annular slide 7 is shifted by an electro-magnetic control element 9, by means of an engaging head 11 being disposed eccentrically on a remote end of the magnetic control element shaft 10 which is oriented toward the annular slide 7, with the head 11 being adapted to engage an aperture 12 disposed in the jacket face of the annular slide 7. The shaft 10 is fastened to a rotating armature 13 disposed between the pole pieces 14. The magnet is excited by means of a coil 15. The magnetic control element 9 is fastened to the pump housing 16 and covered by a housing cover 17 of the pump housing.
While FIG. 1 shows the described parts mostly in cross section, FIG. 2 shows a plan view of the control element 9 with the housing cover 17 removed. The control element 9 is internally stressed by the screws 19, including a guide and bearing 18 of the shaft 10, and the whole assembly is fastened on the housing 16 by screws 20 and 21. Between screws 20 and 21 is disposed a corrugated washer 34, which is pre-stressed during the adjustment process. In this first exemplary embodiment, essentially shown in FIG. 2, the control element 9 can be rotated on the screw 20, which serves as a shaft, essentially in the amount which--as shown in FIG. 3--the shaft of the assembly screw 21'" allows in the bore 22 in the base plate 23 of the control element 9. The base plate 23 is solidly connected with the guide part of shaft 10. The rotation is accomplished by means of an adjustment screw 24, which moves in a threaded bore of the pump housing 16 and which has a conical portion 25, which acts in concert with a corresponding chamfered face portion 26 of the base plate 23. When turning the adjustment screw 24 forward--seen in conjunction with FIG. 2--the control element 9 is rotated to the right, so that the shaft 10 and with it the engaging head 11 are also displaced towards the right, in the direction of larger amounts of injected fuel, in accordance with FIG. 1. After adjusting the control element 9, it is fastened by tightening of the screws 20 and 21.
The variation shown in FIG. 3 has the adjustment screw 24'" in the form of a threaded spindle, which moves in a sleeve 27 which is screwed into a tap hole of the housing cover 17. This makes it possible to make the adjustment during operation and with the cover closed. After the adjustment is accomplished, the sleeve 27 and the screw 24'" are removed and the bore is closed with a plug element.
In accordance with the present invention the assembly screws 21'" can be formed elongated, so that the screw head is guided in a bore in the housing cover 17, which makes it possible to use a suitable instrument for actuation thereof from outside of the cover. Between the parts of the screw and the housing cover, suitable sealing rings are provided.
The cross section and view of the second exemplary embodiment shown in FIGS. 4 to 6 correspond with those in FIG. 1. In contrast to the first exemplary embodiment, in this second exemplary embodiment the control element 9 is only moved in a straight line on the housing. The parts corresponding to the first exemplary embodiment have the same reference numbers, but with the prime added. The base plate 23' is fastened to the housing 16' by screws 21'. The adjustment is accomplished by means of an adjustment screw 24', which is guided in the housing 16' and the conical section 25' of which acts with the respective conical face 26' of the base plate 23'. To make the adjustment, the tightening screws 21', moving in slotted holes, are loosened and the base plate 23' is displaced against two springs 28 by the adjusting screw 24'. After adjustment the two screws 21' are fastened as in the first exemplary embodiment. To make turning of the adjustment screw 24' from outside of the housing possible, an adjustment tool 29 (shown by broken lines) which acts on the hexagonal inner part of the head of screw 24' is disposed inside of the housing cover 17'.
In the variation of this second exemplary embodiment shown in FIG. 6 the movement of the base plate 23' is accomplished by a servomotor 30, as a variation of an automatic adjustment.
The control element is tilted for the adjustment in the two variations of the third exemplary embodiment shown in FIGS. 7 and 8. The parts equivalent to those in the foregoing examples have the same reference numbers, but with a double prime added. The base plate 23" can be tilted around a shaft 32, shown only in projection, and the base plate 23" is disposed in the area of this shaft on the housing 16". For this, a simple bulge on the base plate 23" in the main direction of the shaft 32 is sufficient. The base plate 23" is secured against movement or turning in its position by means of fastening screws 21", of which only one has been shown by dotted lines as being invisible, and where the bores 22" containing the screw permit a certain tilting movement of the plate. The adjustment screw 24" moves, as in the other exemplary embodiments, inside the housing 16" and more or less tightens an elastic ring 33 disposed between the housing 16" and the base plate 23". The more the ring 33 is compressed, the more the engaging head 11" of the shaft 10" is moved to the right.
In the exemplary embodiment shown in FIG. 7, the elastic ring is composed of a spring in the form of two plate springs or a corrugated washer; and in the variation of the third exemplary embodiment shown in FIG. 8, the ring 33 consists of an elastic plastic ring. Because of the transformation ratio, i.e., the distance of screw 24" from shaft 32 or the distance of the engaging head 11" from the shaft 32 the displacement of the head 11" is only two-thirds of the tilt path of the base plate 23" at screw 24".
To have a self-securing and elastic connection, a corrugated washer 34 can be disposed in all exemplary embodiments between the head of the tension collar of the assembly screw 21 and the base plate 23.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | A rotary magnet control element for a distributor injection pump is proposed, which is universally movable by an adjustment means while an engine in running for adjustment of the position of the rotary magnet relative to an annular slide which is reciprocably disposed on a pump piston. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Application No. 60/319,547, filed Sep. 12, 2002 is claimed.
BACKGROUND
Sustained casing annulus pressure (SCP) due to the influx of pressured liquids or gases, water or hydrocarbon, from unknown points of entry and at unknown depths is a large-scale problem and presents safety hazards and regulatory concerns in the oil and gas industry. It is estimated that over 8,000 wells and 11,000 annuli are affected in the offshore Gulf of Mexico Region. A failure to control the casing annulus pressures below maximum allowable limits may result in a well blowout or other uncontrolled event that may result in significant loss of property, environmental impact, and potentially loss of life.
The injection of high-density brine solutions into the casing annulus has typically been used to control the casing annulus pressure. However, injecting or displacing denser fluids into the casing annulus of a well, without having to undergo significant well operations is difficult. The principle difficulty arises from the fact that often the casing annulus space, into which the fluid must be injected, is sealed on both ends and may be an inner or outer string without access other than through a valve on the casing head or spool. This makes the displacement of the existing fluid in the casing annulus space very difficult.
Current technologies often rely upon the systematic injection and bleed off of small amounts of brine fluid resulting in the over dilution of the more dense brine fluid. As the more dense brine fluid is injected and begins to drop through the less dense fluid, it also begins to disperse and mix with the less dense fluid; the hydrostatic pressure in the casing may thus increase somewhat due to the injection of the more dense brine into the casing annulus, but the more dense brine will not have dropped all the way to the bottom of the well; therefore, when it is time to bleed off fluid from the top to permit additional more dense brine to be injected, some of the more dense brine injected previously is dispersed in that which is bled off. Also, now the density of the fluid at the top of the casing is more dense than it was before, therefore the next injection of more dense brine will be attended with a slower rate of falling through the increasingly more dense top fluid and a greater degree of dispersion of the one into the other. Eventually this process of injection and bleedoff becomes self-limiting, often without increasing the hydrostatic pressure within the casing annulus enough to bring the casing pressure under control or even to keep up with the rate of increase in pressure. Injection tubes can be inserted to direct the injection of more dense brine slightly below the surface. However, these injection systems have not produced consistent results.
Thus, there exists a need for a top down process to introduce dense fluid, which is effectively immiscible, and drops without dispersing to the bottom of the annulus, efficiently displacing the less dense fluid, and raising the pressure in the casing annulus to the point where the pressure within the casing annulus is equal to or greater than that of the influx of fluids or gases, water or hydrocarbon, that had been bleeding into the annulus previously.
SUMMARY
The present invention addresses the ongoing industry need for an effective top down surface remediation process for lowering or eliminating sustained casing annulus pressure within an annulus due to the influx of formation or reservoir fluids by injecting fluids and additives with a rig-less injection process without interrupting well production. The preferred process introduces high-density brines, which have been engineered to be cohesive and non-dispersive, or effectively immiscible, by injection into the casing annulus or annuli of a well through a surface annulus valve while taking returns through a second annulus valve.
In one alternative illustrative method, the fluid is injected into a pressured annulus or annuli at the surface through a casing annulus valve by repetitive injection and bleedoff process called lubricating. The preferred illustrative embodiment of the process is carried out by injecting fluids of higher density, which have been engineered to be cohesive and non-dispersive, and allowing them to fall due to the pull of gravity.
The process involves fluids composed of a brine solution, viscosifying additives, for example biopolymers such as xanthan gum or modified xanthan gums or other biopolymer variants, hydroxethycelluloses and other known viscosifiers, which may be engineered or combined with or require rheology modifiers, surface tension reducers, thermal stabilizers, coalescing agents, soluble or insoluble weighting or bridging agents, sealants or other functional additives as determined by primary treatment response. The more dense fluids effectively behave like a separate, cohesive, immiscible phase as they drop without dispersing through a less dense fluid. As the denser fluid drops to the bottom of the casing annulus, the less dense fluid is simultaneously displaced to the top of the casing annulus where it subsequently is bled off simultaneously or by cyclic lubrication. In this manner the denser fluid displaces the less dense fluid and thus the density of the fluid column in the annulus is increased. By raising the density or hydrostatic pressure in the fluid column, further influx of pressured fluids or gases from the non-isolated source, in the production string or pressured formations, is prevented or mitigated and the casing annulus pressure is brought under control or into regulatory compliance.
These and other features of the present invention are more fully set forth in the following description of preferred or illustrative embodiments of the invention.
DETAILED DESCRIPTION
The present invention uses a preferred method of top down surface injection of high-density viscosified fluids and additives injected at the surface through a casing annulus valve while taking returns through a second casing annulus valve. The denser fluids are viscosified and drop rapidly through the unviscosified less dense annulus fluid without dispersing, displacing it with the more dense fluid and controlling the influx of gas or fluids. An alternative less optimal approach would be to inject through a single annulus valve when a second valve is not present using cycles of injection and bleed down known as lubrication. Another lubricating method utilizes a CARS unit (Casing Annulus (Pressure) Remediation System), which usually requires that the well be bled down to zero pressure while a small surface port, or tube is run into the annulus. This would not be possible in most situations as the further influx of fluid will be uncontrolled or accelerate, etc., and present unacceptable risks. Additionally, there would be a high likelihood that the port or tube would encounter some sort of obstacle or a narrowing or restriction of the small volume into which it was being inserted long before it had been extended into the deeper reaches of the annulus. As a result, it is extremely unlikely that the port or tube could be pushed down to a significant fraction of the total depth of the annulus into which it was being inserted. To access the deeper reaches of the annulus, the fluid would have to be engineered to fall much farther than the deepest extent of the port or tube without significantly commingling with the fluid already in the annulus. Lubricating a denser fluid into an annulus in small volumes that must drop through the less dense fluid through a process of injection and bleeding off of the less dense surface fluid raises the density in the annulus more slowly than the continuous injection and simultaneous bleed-off process.
A brine fluid with a significant density differential with respect to the less dense fluid can be formulated which can be injected rapidly or slowly and can fall rapidly through 200° F. CaCl 2 brine without readily dispersing. The fluid should fall through the less dense brine and should be cohesive enough to make it to the bottom or far enough down hole without dispersing to displace the less dense fluid as it settles to the bottom.
The fluids of the present invention generally comprise a liquid brine solution, a xanthan gum or an uncoated xanthan gum, and/or additional viscosifiers, rheology modifiers, surface tension reducers, thermal stabilizers, coalescing agents, oxygen scavengers, and corrosion inhibitors, but may also contain weighting and bridging agents, sealants and a variety of other additives to improve functionality.
The brines useful for the present invention include halide brines, formate brines, and acetate brines, such as, for example, those based on ZnCl 2 , ZnBr 2 , CaBr 2 , ZnBr 2 /CaBr 2 blends, ZnBr 2 /CaBr 2 /CaCl 2 blends, KBr, KI, KHCO 2 , KCH 3 CO 2 , CsBr, CsI, CsHCO 2 , CsCH 3 CO 2 , mixtures thereof and of similar compounds known to one of skill in the art.
The biopolymer xanthan gums useful for the present invention, but not all inclusive, include Flo-Vis, a premium grade, clarified water-dispersible xanthan gum available from M-I, LLC, and Flo-Vis L, a liquid, premium grade, clarified xanthan gum that is not glyoxal-coated and that is suspended in a water-miscible carrier fluid. Flo-Vis L is also available from M-I, LLC. Viscosifiers useful for the present invention include the following: Duo-Vis, a premium grade, high-molecular-weight biopolymer available from M-I, LLC, scleroglucan, hydroxyethyl cellulose (HEC), derivatized starches, synthetic polymers such as poly(ethylene glycol)(PEG), poly(diallyl amine), poly(acrylamide), poly(aminomethylpropylsulfonate[AMPS]), poly(acrylonitrile), poly(vinyl acetate), poly(vinyl alcohol), poly(vinylamine), poly(vinyl sulfonate), poly(styryl sulfonate), poly(acrylate), poly(methyl acrylate), poly(methacrylate), poly(methyl methacrylate), poly(vinylpyrrolidone), poly(vinyl lactam), co-, ter-, and quater-polymers of the following co-monomers: ethylene, butadiene, isoprene, styrene, divinylbenzene, divinyl amine, 1,4-pentadiene-3-one (divinyl ketone), 1,6-heptadiene-4-one (diallyl ketone), diallyl amine, ethylene glycol, acrylamide, AMPS, acrylonitrile, vinyl acetate, vinyl alcohol, vinyl amine, vinyl sulfonate, styryl sulfonate, acrylate, methyl acrylate, methacrylate, methyl methacrylate, and vinylpyrrolidone or another vinyl lactam.
The thermal stabilizers, rheology modifiers, and coalescing agents useful for the present invention include but are not limited to lipids, fatty acid derivatives, tall oils, pH additives, alcohol esters, polysaccharides, amines and amine derivatives, glycol derivatives, and primary, secondary, and tertiary alcohols. The amine derivatives include the miscible amine derivatives, triethanolamine, methyldiethanol amine (MDEA), dimethylethanol amine (DMEA), diethanol amine (DEA), monoethanol amine (MEA), diglycolamine (DGA) or other suitable tertiary, secondary, and primary amines and ammonia. Additionally, methyldiethanol amine, dimethylethanol amine, diethanol amine, monoethanol amine, or other suitable tertiary, secondary, and primary amines and ammonia could be substituted, in whole or in part, for the triethanolamine. Suitable glycols and glycol derivatives include ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, ethylene propylene glycol, and the like. Suitable alcohols would include methanol, ethanol, propanol and its isomers, butanol and its isomers, pentanol and its isomers, hexanol and its isomers. In addition, it also is expressly within the scope of the invention that other mixed TEA systems may be used as additives, such as a TEA/glycol system or a TEA/alcohol system, as well as other mixed amine systems such as a DMEA/glycol system or a MDEA/alcohol system.
Sealants, weighting and bridging agents, and other additives may be useful in partial application or as system treating agents depending on the severity of the source of influx and the success or failure of the primary preferred system treatment. In general it is believed that most leaks falling within the MMS guidelines for bleed-down and rate of pressure build-up and maximum allowable pressure are one-way or of such a magnitude and rate to require rig intervention.
Generally it should be appreciated by one of skill in the art that many of the fluids of the present invention exhibit sufficient low-shear-rate rheology to be cohesive and maintain phase separation without dispersion. In addition the fluids have been designed to fall rapidly, and thus displace a less dense brine in the casing annulus. Finally, the fluids of the present invention should most preferably settle with a sharp interface on the bottom of the casing annulus. This combination of properties permits the injection of the fluid into the casing annulus without having to undertake the sequential injection process described in the alternative process or prior art. In addition, the fluids of the present invention will permit the injection of fluids into the casing annulus without having to utilize specialized injection tubing or other means of injection.
In a report entitled, Diagnosis and Remediation of Sustained Casing Pressure in Wells by Andrew K. Wojtanowicz, Somei Nishikawa, and Xu Rong, Louisiana State University, (submitted to the U.S. Department of the Interior, Minerals Management Service), studies were described which show that a strong relation exists between the performance of cyclic injection and chemical interaction of the brines with fluids (usually drilling muds) already in the annulus. Depending upon fluid compatibility, the performance might range from total elimination of casing pressure to extreme cases of no effect at all. Field observations have confirmed this conclusion. Furthermore, a key specific conclusion that can be drawn from this study is that an immiscible combination of kill and annulus fluids provides the most desirable performance for cyclic injection. In this case, the injected fluid would displace the annular fluid and kill the sustained casing pressures. It would seem from the conclusions of the LSU report that the best way to practice the art of the present invention would be to inject effectively immiscible or completely immiscible fluids rather than miscible fluids. However, there are many cases in which the injection of an immiscible higher density fluid into a well is impractical for economic reasons or for technical reasons such as, for example, that the immiscible fluid would have an unacceptable HSE profile, would interact adversely with elastomers already present in the well, or would lead to excessive corrosion when (as is the most likely situation) corrosion inhibitors compatible with both of the immiscible fluids could not be found. Another technical consideration involves the possibility that some wholesale leakage would occur, for example, in the case of parted casings or tubing, and the immiscible fluid could come into contact with yet another fluid with which an adverse incompatibility problem might arise. The same could be the for miscible fluids in some cases; however, with miscible fluids, these adverse incompatibility problems are typically much less likely. Parted casing or tubing very often begins with a leak or mechanical failure at the threads. Casing and tubing threads are increasingly susceptible to gas and fluid leaks with time, length, torque, heating/cooling, hardness, pressure, etc. Particular thread types seem more susceptible to one-way gas leaks and more so in jointed pipe run without isolation rings or seals.
The LSU report described above, entitled, Diagnosis and Remediation of Sustained Casing Pressure in Wells, does in fact capture a key element of truth in the need to utilize fluids that are immiscible. Accordingly, the teachings in accordance with the present invention are to inject fluids of higher density, which have been engineered to be cohesive and non-dispersive, and allowing them to fall due to the pull of gravity. The engineering to render the fluids cohesive and non-dispersive involves beginning with a higher density fluid that is miscible with and inherently compatible with the lower density fluids already in the annulus of the well. Then the addition of rheology modifiers and additives that cause surface tension reduction, coalescence, and thermal stabilization alters the performance of the higher density fluid so that, surprisingly, it behaves much like an immiscible fluid in the key respect that it can fall through the lower density fluid without dispersing therein.
Typically, the method of injection of the fluids in accordance with the present invention, comprises the steps of rigging up to the top of the annulus of the well through two valves, into one of which the higher density fluid is injected and from the other of which the lower density fluid is withdrawn. If the higher density fluid is properly engineered in accordance with the compositions of the present invention, it will drop through the lower density fluid into the deeper reaches of the annulus and will not short circuit through the top of the annulus to the valve from which the lower density fluid is intended to be withdrawn.
In another embodiment of the invention, the higher density fluid is injected through a CARS setup. This embodiment is similar to that just described above, except that the injection valve should be a ball valve with a large enough orifice that a length of smallbore tubing can be pushed through the orifice and reaching down some distance beyond the valve and into the deeper reaches of the annulus. This CARS arrangement will increase the distance between the injection point and the withdrawal valve, reducing somewhat the likelihood that the denser fluid would short circuit through the top of the annulus to the valve from which the lower density fluid is intended to be withdrawn. Nevertheless, it is recommended that even with the CARS configuration, the higher density fluid should be properly engineered in accordance with the compositions of the present invention, so that it will drop through the lower density fluid into the deeper reaches of the annulus and will not short circuit through the top of the annulus to the valve from which the lower density fluid is intended to be withdrawn.
The following example is included to demonstrate a preferred embodiment of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the example which follows represent techniques discovered by the inventors to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the scope of the invention.
Unless otherwise stated, all starting materials are commercially available and standard laboratory techniques and equipment are utilized. The tests were conducted in accordance with the procedures in API Bulletin RP 13B-2, 1990. The following abbreviations are sometimes used in describing the results discussed in the examples: Values of viscosity are measured at the given rpm rate.
“PV” is plastic viscosity (CPS) which is one variable used in the calculation of viscosity characteristics of a drilling fluid.
“YP” is yield point (lbs/100 ft 2 ) which is another variable used in the calculation of viscosity characteristics of drilling fluids.
“F/L” is API fluid loss and is a measure of fluid loss in milliliters of drilling fluid at 100 psi.
EXAMPLE 1
The following example illustrates the properties and characteristics of the fluids formulated in accordance with and for use with the present invention.
LABORATORY PROCEDURES: 100 ml graduated cylinders were filled with 11.6 ppb CaCl 2 brine and heated to 200° F. in a water bath. Individual cylinders were then removed from the bath and 20 mls of test fluid were injected into the cylinder using a syringe. Each of the test fluids was formulated in accordance with the present invention and generally were composed as follows: Test Fluid A is an 18.6 ppb brine containing 4 ppb Flo-Vis L.
Test Fluid B is an 18.6 ppb brine containing 4 ppb Flo-Vis L and 2 ppb Safe-Buff, an inorganic (MgO) buffer.
Test Fluid C is an 18.6 ppb brine containing 4 ppb Flo-Vis L and 2 ppb Safe-Buff, and 3% by volume of ECF-687 which is a mixture of 2,2,4-trimethyl-1,2-pentadiol monoisobutyrate (CAS 25265-77-4) and C 16 -C 18 fatty acids (CAS 67701-07-9).
Test Fluid D is an 18.2 ppb brine containing 4 ppb Flo-Vis L.
Test Fluid E is an 18.2 ppb brine containing 4 ppb Flo-Vis L and 2 ppb Safe-Buff, and 3% by volume of ECF-687 which is a mixture of 2,2,4-trimethyl-1,2-pentadiol monoisobutyrate (CAS 25265-77-4) and C 16 -C 18 fatty acids (CAS 67701-07-9).
The properties of each of the test fluids is given in Table 1 below:
TABLE 1
Test Fluid
A
B
C
D
E
600 rpm
90
106
112
154
206
300 rpm
57
67
72
106
146
200 rpm
46
54
60
86
124
100 rpm
30
35
39
64
97
6 rpm
7
8
10
23
42
3 rpm
4
5
7
18
35
PV
33
39
40
48
60
YP
24
28
32
58
86
LSRV, 1 min.
70385
LSRV, 2 min.
71185
LSRV, 3 min.
71185
LSRV, 6 min.
70985
In view of the above, one of ordinary skill in the art should appreciate that the fluids of the present invention posses a sufficient density and viscosity to be cohesive and not be dispersed during the injection process. Also it should be appreciated that the fluids of the present invention should be capable of rapidly sinking under the influence of gravity and thus should be capable of displacing less dense fluids in a casing annulus.
While the apparatus, compositions and methods of this invention have been described in terms of preferred or illustrative embodiments, it will be apparent to those of skill in the art that variations may be applied to the process described herein without departing from the concept and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the scope and concept of the invention as it is set out in the following claims. | A method of injection of a higher density fluid into the top of the annulus of a well while lower density fluid is withdrawn from the top of the annulus of the well, wherein the higher density fluid has a composition such that it will drop through the lower density fluid without dispersing therein, thus flowing into the deeper reaches of the annulus and not short circuiting through the top of the annulus to the point from which the lower density fluid is intended to be withdrawn. A method of injection of a higher density fluid into the top of the annulus of a well without simultaneously withdrawing a lower density fluid from the top of the annulus of the well, wherein the higher density fluid has a composition such that it will drop through the lower density fluid without dispersing therein, thus flowing into the deeper reaches of the annulus so that when the pressure induced in the annulus as a result of this injection is subsequently bled off, principally the lower density fluid will be that which is withdrawn. | 2 |
BACKGROUND OF THE INVENTION
The invention pertains to monitor circuits for rechargeable multicell battery packs.
Rechargeable batteries are widely used in standby power applications to provide temporary service during power outages and the like. Typical applications are to industrial emergency lighting systems, fire alarm systems, burglar alarms and computer systems. Because it is extremely important that the batteries operate reliably when called upon, monitor circuits are often employed for monitoring their condition and for providing an indication of any battery malfunction, should that occur. These monitor circuits normally merely sense the battery output voltage to detect when it falls below a given value. However, this is often not an accurate measure of battery condition since the output voltage of rechargeable batteries varies with such factors as temperature, load and age. In particular individual battery cells may be in a partially or completely deteriorated condition and yet not sufficiently affect the output voltage so as to be detectable by conventional circuits.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a novel and improved battery monitor circuit for rechargeable multicell battery packs which detects battery condition with extreme accuracy and reliability.
It is another object of the invention to provide a novel and improved battery monitor circuit which detects numerous defective conditions with respect to a rechargeable multicell battery pack.
It is a further object of the invention to provide a novel and improved battery monitor circuit capable of detecting the presence of a partially or completely defective cell within a rechargeable multicell battery pack.
It is yet a further object of the invention to provide a novel and improved battery monitor circuit as above described which is of relatively simple circuit design and low cost.
The present invention takes into account the fact that cells within a rechargeable battery pack are closely matched in their manufacture and under identical conditions will exhibit the same voltage, to within a few millivolts. When a cell deteriorates its load characteristics or impedance changes and it eventually becomes a shorter or open cell. By continuously comparing the cells against each other, the overall battery condition can be determined independent of the effects of temperature, age and load, and often in the incipient stages of battery failure.
Accordingly, the above recited and other objects of the invention, in accordance with one aspect thereof, are accomplished by a battery monitor circuit for a multicell rechargeable battery having a high voltage terminal and a reference terminal at opposite ends and an intermediate terminal that divides the cells of the battery into two groups, comprising resistive voltage divider means for providing a first signal of voltage magnitude in a range corresponding to the ratio of the number of cells within said two groups when coupled across the battery's high voltage and reference terminals. Means coupled to said intermediate terminal provides a second signal of voltage magnitude corresponding to the voltage between said intermediate and reference terminals, and comparison means responsive to said first and second signals generates an error signal upon a signal change sufficient to cause reversal of the relative voltage magnitude of said first and second signals, which is indicative of battery cell deterioration.
In accordance with a more specific aspect of the invention, at any given instant said first signal is composed of first and second voltage magnitudes which define the limits of said range, said second signal is composed of a third voltage magnitude, said first and second voltage magnitudes being nominally offset to either side of said third voltage magnitude, and said comparison means comprises a first comparator network responsive to said first and third voltage magnitudes and a second comparator network responsive to said second and third voltage magnitudes. In addition, said voltage divider means comprises a series resistance divided into first and second large resistance components joined by a relatively small third resistance component, said first voltage magnitude being derived from the junction of said first and third resistance components and said second voltage magnitude being derived from said second and third resistance components, whereby said error signal is generated when the input voltages to either of said first or second comparator networks change sufficiently so as to experience a reversal in relative magnitude.
In accordance with a further aspect of the invention, there is provided further comparison means responsive to a reference signal of reference voltage magnitude and a further signal of voltage magnitude in a range that is a function of the voltage across all the cells of said battery for providing a further error signal when the voltage magnitudes of said reference and further signals experience a reversal in relative value, which is indicative of a multiple cell failure.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with the claims which particularly point out and distinctly claim that subject matter which is regarded as inventive, it is believed the invention will be more clearly understood when considering the following detailed description taken in connection with the accompanying figures of the drawings, in which:
FIG. 1 is a schematic circuit diagram of a battery monitor circuit, in accordance with the invention; and
FIG. 2 is a simplified schematic diagram useful in explaining the operation of the circuit of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, there is illustrated a battery monitor circuit 2 for a multicell rechargeable battery pack 4 employed for standby power, which circuit detects various defective conditions of the battery so as to ensure a reliable operation when the battery is called into service due to interruption of power from the normal source of supply, denoted by transformer winding 6. As illustrated in the drawing, upon power interruption the normally open relay contacts 8 close for connecting the battery across a load 10 that may be an emergency light or take any number of other forms for which standby battery power is useful.
The battery 4 is composed of multiple cells, typically twelve in number, which are closely matched in their manufacture so as to exhibit the same voltage to within several millivolts under identical test conditions. In the exemplary embodiment under consideration, a nickel-cadmium battery was employed, although for purposes of the invention any rechargeable multicell battery providing an accessible intermediate voltage tap or taps may be employed. When a battery cell deteriorates its load characteristic or impedance changes, either decreasing toward an eventual short circuit, or increasing toward an eventual open circuit. The impedance of a cell, as the term is used herein, may be defined as the cell voltage divided by cell current. As will be seen, the present monitor circuit 2 detects the deterioration of one or more cells prior to the occurrence of a substantially shorted or open condition.
Charging current is supplied to the battery through a diode 12 connected in the forward poled direction between power supply terminal 14 and the high voltage terminal 16 of battery 4, which also has a ground terminal 18 and an intermediate terminal 20. The terminal 20 divides the cells of the battery into two groups. It is preferable that terminal 20 be situated so as to provide a relatively balanced grouping of the cells, and that in the normal condition the voltage across a single cell is a substantial fraction of the total voltage across its group of cells, e.g., no less than 1/10, so that any change in cell impedance is readily detectable. In the present example, terminal 20 is a center tap placing half the total number of cells in each of the upper and lower groups, although for purposes of the invention other intermediate terminal taps may be employed. A resistive voltage divider composed of serially connected resistors 22, 23 and 24 is connected across the battery between terminals 16 and 18. Resistors 22 and 24 are more than an order of magnitude greater than resistor 23, and in the present example are of equal value. A terminal 26 is at the junction of resistors 22 and 23, and a terminal 28 at the junction of resistors 23 and 24. Resistors 22 and 24 serve to divide the battery voltage in accordance with the ratio of the number of cells within the two groups. Resistor 23 is an offset resistor that serves to provide a narrow range of voltages or threshold window, about the nominally divided voltage. Thus, for a battery in satisfactory condition, the voltages at terminals 26 and 28 are slightly higher and slightly lower, respectively, then half the battery voltage, which is at terminal 20.
Terminal 20 is coupled through an impedance matching resistor 30 to the positive input of a first comparator network 32 and to the negative input of a second comparator network 34. Terminal 28 is applied to the negative input of comparator 32, and terminal 26 is applied to the positive input of comparator 34. As will be further described, comparators 32 and 34 respond to the deterioration of one or more cells to change output state from a normal high impedance output state to a low impedance output state. Also included in the monitor circuit are comparator networks 36 and 38 which respond to conditions of two similarly deteriorated cells in each group of the battery pack, or abnormally high or low battery output voltage. The comparator networks are conventional circuit components for generating one of two digital output signals in response to the relative magnitude of a pair of input signals. The outputs of comparators 32, 34, 36 and 38 are connected in an OR configuration and coupled to the base of an NPN transistor 40. The emitter of transistor 40 is connected to ground and the collector is connected through a monitor lamp 42 and forward poled diode 44 to power supply terminal 14. For a normal operation, transistor 40 conducts and lamp 42 will be on. When any one of the comparators changes output state in response to an abnormal condition, which bypasses the base drive current, or should the power fail, transistor 40 is made nonconducting and the monitor lamp goes out.
Diode 44 is further coupled through a resistive voltage divider of serially connected resistors 46 and 48 to ground, the function of these resistors being applied to the negative input of comparator 38. Diode 44 is also coupled through a resistive voltage divider of serially connected resistors 50 and 52 and through zener diode 54 to ground, the junction of the zener diode and resistor 52 being applied to the positive input of comparator 38. The junction of resistors 50 and 52 is coupled through a noise filtering capacitor 56 to ground and to each of the comparators for enabling these components, which in the present exemplary embodiment are enabled only during the charge cycle by virtue of the operation of diodes 12 and 44. A conductor 58 provides a ground connection for each of the comparators. Finally, a current limiting resistor 60 is connected between the diode 44 and the base of transistor 40, resistor 60 supplying base drive current for turning on the transistor. While there is some advantage regarding current identification in operating the circuit only during the charge cycle, for purposes of the invention the circuit may be modified to operate in the discharge cycle with comparable results.
In operation of the battery monitor circuit of FIG. 1, under normal conditions with the battery 4 is satisfactory condition and a proper voltage applied to the battery by the power supply, the comparators are all in their normal high impedance output stage for supplying a signal to the base of transistor 40 that allows base drive current from resistor 60 to maintain this transistor in a conductive mode, lighting the monitor lamp 42. In the present example, the battery is assumed to have 1.3 volts per cell between 0° C. and 70° C., generating 15.6 volts across terminals 16 and 18. Referring to FIG. 2, which is a simplified representation of the battery and its parallel resistive voltage divider network of equal resistors R 1 and R 2 , under normal conditions the output battery voltage V o is 15.6 volts, the voltage V m at the center tap is 7.8 volts and the voltage 1/2V o at the junction of resistors R 1 and R 2 is also 7.8 volts. Should a cell become shorted, V o will drop in voltage by 1.3 volts and 1/2V o will drop by 0.65 volts. If the shorted cell is one of the lower cells V m will drop by 1.3 volts, and if one of the upper cells V m will remain the same. In either case, however, V m no longer equals 1/2V o . As will be seen, it is this inequality that triggers the response of comparators 32 and 34. Similarly, if a cell substantially increases in impedance, 1/2V o will increase by a certain amount and V m will increase by twice this amount or remain the same, depending upon the deteriorating cell being one of the lower or upper cells, respectively. It may also be noted at this point that for the rare occurrence of where there should develop an equal deterioration of cells in both the upper and lower cells, such as a shorted cell in each, the equality between V m and 1/2V o is not upset. In such case one of comparators 36 and 38 is made to function, as will be described subsequently.
The resistor 23 of the resistive voltage divider across battery 4 provides an acceptable threshold window for operation of the comparators 32 and 34. The value of this resistor relative to that of resistors 22 and 24 determines the sensitivity of the circuit, or width of the window, and depends on the number of cells in the battery pack and the voltage drop across each cell. With circuit variations and cell mismatch held to under 0.10 volts, a threshold window of between 0.10 and 0.55 volts may be used. In the present example, for normal conditions the voltage at terminal tap 20 is 7.8 volts, with a window of ±0.275 volts which provides good immunity to circuit variation and readily detects a 50% change in any cell impedance. This window value is provided by proportioning the resistance of resistor 23 to that of equal resistors 22 and 24 by approximately 1:13.5. Accordingly, the voltage at terminal 28, which is applied to the negative input of comparator 32, is 0.275 volts less than the voltage at terminal 20, which is applied to the positive input of comparator 32. Correspondingly, the voltage at terminal 26, which is applied to the positive input of comparator 34, is 0.275 volts greater than the voltage applied to the negative input from terminal 20.
Should a cell between terminals 20 and 18 short, the voltage at terminal 20 will drop by 1.3 volts and the voltage at terminals 26 and 28 will drop by 0.65 volts. This causes comparator 32 to change to its low impedance output state by virtue of a reversal in relative magnitude of voltages at the inputs, with the positive input dropping below the negative input, so as to turn off transistor 40 and monitor lamp 42. Should a cell between terminals 16 and 20 short, the voltage at terminal 20 does not change while the voltages at terminals 26 and 28 drop by 0.65 volts. This causes comparator 34 to change to its low impedance output state by virtue of a reversal in relative magnitude of voltage inputs and turn off transistor 40. Correspondingly, should a cell between terminals 20 and 18 substantially increase in impedance so that the voltage drop across the cell increases by 50% of its normal value or more, e.g., by 0.65 volts, the voltage at terminal 20 will increase by this amount and the voltage at terminals 26 and 28 will increase by one half this amount, sufficient to cause comparator 34 to change output state. Should a cell between terminals 16 and 20 substantially increase in impedance to this degree, the voltage at terminal 20 will not change as the voltage at terminals 26 and 28 increases, causing comparator 32 to change output state.
As noted previously, if a shorted cell or high impedance cell develops in both upper and lower groups of the battery cells equal voltage changes occur at terminals 20, 26 and 28 and comparators 32 and 34 will not respond. For the condition of one or more shorted cells in both upper and lower groups of cells, the voltage at terminal 26, which is also connected to the positive input of comparator 36, drops sufficiently so as to fall below the reference voltage of zener diode 54 applied to the negative input, thereby changing the output state of this comparator and turning off transistor 40 and lamp 42. In the present example, the zener diode provides a reference voltage at 1 volt below the nominal voltage at terminal 20. Comparator 36 is also actuated to change output state if the supply voltage falls substantially, i.e., by the amount of two cell voltage drops.
For the condition of one or more high impedance cells in both upper and lower groups of cells, providing a voltage increase of at least twice the voltage of a normal cell, the voltage at the junction of voltage divider resistors 46 and 48, which is applied to the negative input of comparator 38, increases sufficiently so as to exceed the reference voltage of zener diode 54 applied to the positive input so as to change the output state of comparator 38. Comparator 38 is also actuated by the supply voltage increasing substantially.
In the noted exemplary embodiment of the battery monitor circuit 2, the following circuit components and values may be employed, being presented for purposes of clear and complete disclosure and in no sense intended to be limiting of the invention:
______________________________________Resistors 22, 24, 46 100 KohmsResistor 23 7.5 KohmsResistors 30, 48 47 KohmsResistor 50 1 KohmResistor 52 7 KohmsResistor 60 5.6 KohmsCapacitor 56 .1 μfTransistor 40 Type 2N2222AZener Diode 6.8 vDiodes 12, 44 Signal diodesComparators 32, 34, 36, 38 IC 3302______________________________________
While the invention has been described with reference to a specific embodiment thereof for the purposes of clear and concise disclosure, it should be understood numerous modifications may be made to the present circuit by ones skilled in the art that would not exceed the basic teachings of the invention. For example when considering a battery with numerous cells, in order for the normal cell voltage to be a substantial fraction of the total voltage in its group of cells two or more intermediate terminal taps may be employed for dividing the battery cells into three or more groups, with a resistive voltage divider network and a pair of comparator networks provided for each intermediate terminal tap, the comparators being operated in an OR configuration in accordance with the teaching of the circuit of FIG. 1. For example, for a battery having 24 cells, upper and lower terminal taps may be employed to divide the battery into three groups of eight cells each. A first resistive voltage divider may be placed across the upper and middle group of cells and, with the upper terminal tap, coupled to a first pair of comparators. The second resistive voltage divider may be placed across the middle and lower group of cells and, with the lower terminal tap, coupled to a second pair of comparators. The first and second voltage dividers and comparators are connected in a similar circuit arrangement and function in similar manner to comparators 32 and 34 of FIG. 1. The following claims are intended to include within their meaning the above and all modifications and alternatives of the circuit that fall within the true spirit and scope of the invention. | A battery monitor circuit for rechargeable multicell batteries that provides a reliable indication of battery failure independent of temperature, load and age, by continuously comparing the impedance of the cells of the battery against each other. Comparison means are provided responsive to a first voltage at a tapped terminal of the battery that divides the battery cells into two groups, and to a second voltage that represents a fraction of the battery voltage corresponding to the ratio of the number of cells in each group, said comparison means generating an error signal when said first and second voltages change so as to experience a reversal in relative magnitude, which is indicative of cell deterioration. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/309,052, filed May 10, 1999, now U.S. Pat. No. 6,440,158 which is a division of U.S. patent application Ser. No. 08/453,066, filed May 26, 1995, now U.S. Pat. No. 5,902,268, issued May 11, 1999; which in turn was a division of U.S. patent application Ser. No. 08/287,114, filed Aug. 8, 1994, now U.S. Pat. No. 5,624,392, issued Apr. 29, 1997; which was in turn a continuation-in-part of U.S. patent application Ser. No. 07/929,305, filed Aug. 13, 1992, now U.S. Pat. No. 5,342,301, issued Aug. 30, 1994. The disclosures of these patents and patent applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to heat transfer catheter apparatus for internal body applications, and more particularly, to catheters adapted for delivering heat transfer fluids at temperatures above or below normal body temperatures to selected internal body sites that are relatively remote from the point of entry into the body for specialized medical applications. The heat transfer catheters of this invention may, in one embodiment, comprise fluid lumens that have very thin-walled, high strength sidewalls that are substantially inelastic. In an alternative embodiment, the fluid lumen sidewalls may be elastomeric. In either case, the fluid lumens are readily inflatable under fluid pressure and readily collapsible under vacuum. The heat transfer catheter apparatus of this invention may comprise multi-lumen units having two or more lumens. The heat transfer catheter apparatus of this invention may also, in different embodiments, be used alone or in conjunction with other medical apparatus. The heat transfer catheter apparatus of this invention may also, in different embodiments, comprise single or multi-lumen dilatation balloons.
It is well known in the art to prepare and use catheters for a variety of medical applications. In one familiar application, inexpensive, disposable catheters having one open end and one closed end are utilized as protective sheaths for various medical instruments. The use of such elongated, tubular sleeves as protective sheaths can minimize the costs and problems associated with cleaning and sterilizing medical instruments, such as endoscopes, between uses. In the case of medical optical instruments, such as endoscopes, the protective sleeves may include a “window” portion designed to align during use with the optical portion of the medical instrument.
Typical of the prior art in this field are U.S. Pat. Nos. 4,646,722 (Silverstein et al.) and U.S. Pat. No. 4,907,395 (Opie et al.). The Silverstein et al. patent teaches the use of an endoscope sheath comprising a flexible tube surrounding the elongated core of an endoscope. The flexible tube has a transparent window near its distal end positioned in front of the viewing window of the endoscope. An alternative embodiment of the Silverstein et al. sheath for use with side-viewing endoscopes is shown in FIG. 10 of that patent. In this embodiment, the sheath 110 comprises an end cap 112 of relatively rigid material mounted at the end of a flexible cylindrical tube of elastomeric material 114 formed into a roll 116 . The end cap 112 includes a pair of transparent windows 118 , 120 . The later Opie et al. patent is essentially an improvement invention directed to a method of packaging and installing the endoscope sheaths of the Silverstein et al. patent.
U.S. Pat. Nos. 3,794,091 (Ersek et al.) and U.S. Pat. No. 3,809,072 (Ersek et al.) are directed to sterile sheaths for enclosing surgical illuminating lamp structures that have elongated light transmitting shafts. The sheaths in Ersek et al. are fabricated from films of flexible plastic material, such as vinyl tubing, polyethylene or polypropylene. Ersek et al. prefer a wall thickness of between three and six mils for the required durability, rigidity and transparency. The tip end portion 20 of the sheath is described as a “generally rigid lens element” sealed to the sheath in a continuous sealing line 21 by thermal welding or adhesive bonding.
U.S. Pat. No. 4,957,112 (Yokoi et al.) describes an ultrasonic diagnostic apparatus, the distal end portion of which includes a cover 24 made of a thin, hard, polyethylene sheet that has a window portion 34 along a sidewall. U.S. Pat. No. 4,878,485 (Adair) describes a rigid, heat sterilizable sheath S that provides an outer casing for a video endoscope. The sheath includes a viewing window 32 , a flat disc positioned at the distal end in the optical path of the endoscope. U.S. Pat. No. 4,819,620 (Okutsu) describes an endoscope guide pipe which is rigid and formed from a transparent material such as glass or plastic. In one embodiment shown in FIG. 6 of that patent, a pair of slots in the sidewall of the guide pipe is filled with a transparent material, such as glass, to define a window section 12 f . U.S. Pat. No. 4,470,407 (Hussein) describes a flexible, elongated tube with an elastomeric balloon sealingly mounted at the distal end of the tube for enclosing an endoscope. Inside the body, the balloon can be inflated to facilitate endoscope viewing. U.S. Pat. No. 4,201,199 (Smith) describes a relatively thick, rigid glass or plastic tube 10 which fits over an endoscope. The distal end of the tube in the Smith patent is provided with an enlarged, sealed bulb 12 having a radius of at least 3-4 mm to reduce optical distortion caused by a too-small radius of curvature. U.S. Pat. No. 3,162,190 (Del Gizzo) describes a tube 19 , made from molded latex or similar material, through which an optical instrument is inserted. Viewing is through an inflatable balloon element 24 mounted at the distal end of the tube. U.S. Pat. No. 3,698,791 (Walchle et al.) describes a very thin, transparent microscope drape which includes a separately formed, optically transparent, distortion-free lens for viewing.
In another familiar application, multi-lumen balloon catheters are utilized as dilatation devices for dilating a blood vessel, e.g. a coronary artery, or other body canal. The use and construction of balloon catheters is well known in the medical art, as described for example in U.S. Pat. No. Re. 32,983 (Levy) and U.S. Pat. No. 4,820,349 (Saab). Other patents generally showing the application of various types of balloon catheters include U.S. Pat. No. 4,540,404 (Wolvek), U.S. Pat. No. 4,422,447 (Schiff), and U.S. Pat. No. 4,681,092 (Cho et al.).
It is also well known in the medical art to employ catheters having shafts formed with a plurality of lumens in instances where it is necessary or desirable to access the distal end of the catheter or a particular internal body location simultaneously through two or more physically separate passageways. For example, U.S. Pat. No. 4,576,772 (Carpenter) is directed to increasing the flexibility or articulatability of a catheter having a shaft formed with a plurality of lumens that provide distinct conduits for articulating wires, glass fiber bundles, irrigation, and vacuum means.
It is also known, as shown in U.S. Pat. No. 4,299,226 (Banka) and U.S. Pat. No. 4,869,263 (Segal et al.), to employ multi-lumen catheters with a balloon. The Banka patent shows a double-lumen catheter shaft of coaxial construction wherein the outer lumen carries saline solution to inflate a balloon, and an inner lumen, located coaxially inside the outer lumen, is adapted to receive a stylet or guide wire. In the Banka patent, the double-lumen dilatation catheter is designed to be coaxially contained within the single lumen of a larger diameter guide catheter. In the Banka device, each of the three coaxial lumens is a separate, distinct passageway without any means for fluid passage between two of those lumens. Such fluid passage between lumens could occur only accidentally in the event of a rupture of one of the lumens, and such results are clearly contrary to the intent of that patent.
The Segal et al. patent shows a more complex dilatation catheter apparatus having five separate, non-coaxial lumens ( FIGS. 1 and 2 of that patent) extending through the catheter, including a balloon inflation lumen 18 , a distal lumen 17 , a wire lumen 22 , a pulmonary artery lumen 26 , and a right ventricular lumen 28 . Lumens 17 and 18 extend the entire length of the catheter from the proximal extremity to the distal extremity. Lumen 17 exists through the distal extremity 14 b of the catheter. The distal extremity of lumen 18 is in communication with the interior of balloon 16 to permit inflation and deflation. Lumens 22 , 26 and 28 , on the other hand, only pass partly or completely through the larger diameter, proximal portion 14 a of the catheter. The Segal et al. catheter apparatus is prepared by extrusion (col. 2 , lines 53 and 54 ). Multi-lumen catheters in conjunction with a balloon or inflatable element have also been adapted for a variety of special usages. U.S. Pat. Nos. 4,994,033 (Shockey et al.) and U.S. Pat. No. 5,049,132 (Shaffer et al.) are both directed to balloon catheters adapted for intravascular drug delivery. Both of these patents employ a similar concentric, coaxial, double balloon construction surrounding a central lumen. The larger, outer balloons in both cases include a set of apertures for the delivery of medication to surrounding tissue when the catheter is in place. No fluid connection or passageway is provided between the inner and the outer balloons or the lumens serving those balloons in these patents.
U.S. Pat. No. 4,681,564 (Landreneau) teaches another type of multi-lumen catheter in conjunction with a balloon element. In this patent, a first fluid passage is in communication with the balloon element so as to selectively inflate or deflate it; a second, separate fluid passage has outlet openings at its distal end for purposes of delivering medication or other treating fluid to the body space; and, a third, separate passage has drain openings communicating with the body space so as to drain excess fluids. This patent thus describes a catheter loop whereby treating fluid enters the body through a first lumen and some portion of that fluid leaves the body through a separate second lumen. But, this is clearly not a closed loop in the sense that some portion of the treating fluid remains in the body, and all of the treating fluid must pass through a portion of the human body on its way from the inlet lumen to the drainage passage. Such treating fluid certainly could not contain toxic substances which would poison or harm the body.
U.S. Pat. No. 4, 581,017 (Sahota) and U.S. Pat. No. 5,108,370 (Walinsky) are both directed to perfusion balloon catheters designed to maintain blood flow through a blood vessel during a dilatation procedure, for example an angioplasty. In Sahota, a hollow, central shaft passes through the interior of the balloon element, and apertures in the side wall of the catheter shaft upstream and downstream from the balloon permit blood to flow into the shaft, past the balloon, and back into the blood vessel. A small, separate tube connected to the balloon is used to inflate and deflate the balloon. No fluid connection is provided between the balloon and the central shaft. A generally similar balloon catheter construction is described in Walinsky.
U.S. Pat. No. 4,299,237 (Foti) is directed to an apparatus for transferring thermal energy from a calorized fluid to an ear canal and tympanic membrane. In one embodiment, this apparatus comprises a rigid structure made of a semi-rigid material and pre-shaped so as to conform to the internal geometry of an ear canal. Rigid internal struts keep open a fluid circulation loop served by a fluid inlet tube and a fluid outlet tube. In an alternative embodiment, the Foti apparatus comprises an inflatable balloon element surrounding a hollow, central shaft containing a depth indicator for proper positioning of the device. The balloon element is inflated and deflated through separate fluid inlet and outlet tubes connected through a rigid ear mold adjoining the balloon element. The Foti apparatus in either embodiment is relatively short (typically about 32 mm in length) and relatively wide (overall diameter of about 6 mm), therefore bearing little resemblance to a vascular-type catheter which is typically several hundred millimeters in length but with a diameter of only about three-four millimeters or less. Furthermore, the Foti device is designed to operate only at a relatively low fluid pressure because it is not intended for dilating internal body canals and also because there is no need to force fluid through a very small diameter conduit over relatively long distances, again in contrast to a vascular-type dilatation catheter.
In the above-cited prior art, which is incorporated herein by reference, it should be understood that the term “multi-lumen” in the phrase “multi-lumen balloon catheters” typically means that the catheter shaft is multi-lumen (as opposed to the balloon segment in communication with the catheter shaft). By contrast, my U.S. Pat. No. 5,342,301, of which this application is a continuation-in-part, is directed to novel multi-lumen balloons. The multi-lumen balloons of my aforementioned invention are distinguished from the multi-lumen balloon catheters of the prior art, as discussed above, in that the walls defining the lumens are formed as an integral part of the balloon. The terms “integral part” and “integrally formed” as used in U.S. Pat. No. 5,342,301 each mean that at least a lumen of the multi-lumen balloon shares a common wall portion with part of at least one inflatable balloon segment. By contrast, the prior art shows lumens that are formed as a part of a conventional catheter shaft and are defined by the relatively thick walls of that catheter (e.g., Segal et al.), catheter lumens that communicate with or terminate in a balloon segment (e.g., Banka and Segal et al.), and lumens in a shaft that passes coaxially through a balloon segment (e.g., Banka, Sahota, and Walinsky).
In many conventional and non-conventional medical catheter applications, it would be desirable to provide a means for continuously transferring over an extended time period controlled amounts of thermal energy to or away from one or more adjacent locations along or at the distal end of an elongated, vascular-type catheter. Heat transfer can be effected, of course, by circulating a heat transfer fluid inside a catheter lumen. This straightforward approach is complicated, however, by enormous and heretofore unsurmountable physical limitations and obstacles.
Thus, a single lumen catheter can certainly deliver a heat transfer fluid to the closed distal end of the catheter. But, if the heat transfer fluid is at a temperature different from body temperature, the result of this procedure would be to merely create a temporary temperature gradient along the length of the catheter. At locations distal from the point where the fluid was introduced to the catheter, the temperature of the fluid in the catheter would tend to approach the internal body temperature. Furthermore, even this temperature effect would exist for only a relatively short time until the fluid at every point along the catheter gradually heated or cooled to body temperature. Clearly, this approach cannot be used to continually transfer controlled amounts of thermal energy to or away from internal body locations over an extended time period.
To effect continuous, controlled transfer of thermal energy to or from a body location adjacent the catheter therefore requires, at a minimum, a two-lumen catheter construction. With such a two-lumen construction, a continuous flow of heat transfer fluid can, at least in theory, be established. Fresh fluid at any desired temperature can be continuously introduced at the proximal end of a first or inlet catheter lumen and passed through that first lumen to a distal location inside the body, then passed through fluid connection means directly to the second or outlet catheter lumen, and finally passed back along that second lumen to be withdrawn at the proximal end as spent fluid for discarding or recycling. If the continuous fluid flow rate through such a two-lumen catheter system is sufficiently rapid, this construction makes it possible to establish and substantially maintain a fluid temperature inside the catheter that is above or below normal body temperature at any location along the length of the catheter. Correspondingly, if the catheter is constructed of a material which has good heat transfer properties and which is also sufficiently flexible so as to closely conform to the surrounding body cavity, the temperature of the fluid inside the catheter can be transferred to adjacent portions of the body that are in contact with or in proximity to the catheter sidewalls.
There are problems, however, associated with a two-lumen catheter configuration for carrying heat transfer fluid. A principal problem with such a configuration, utilizing conventional catheter and balloon construction and materials, relates to the size of the final apparatus. It will be apparent to those skilled in the art that catheter constructions intended for blood vessels and similar very small diameter body passages must be of correspondingly small diameter. This size problem is exacerbated by a two-lumen catheter construction, whether the lumens are configured side-by-side or concentrically. In either case, a significant proportion of the limited space inside the blood vessel or other body passage is occupied by relatively thick catheter sidewalls leaving relatively little open cross-sectional area for circulating fluids or as passageways for medical instruments and the like.
For example, the relatively thick sidewalls that define the lumens of conventional multi-lumen catheters, such as in the prior art patents cited above, typically range from about 0.003 to about 0.010 inches or greater. In part, the reason that conventional multi-lumen catheters have utilized such thick sidewalls is because these devices are fabricated from materials that are not high in tensile strength. Most balloon catheter shafts have conventionally been made by extrusion of a thermoplastic material. The resulting shafts are typically not substantially oriented, therefore not high tensile strength. Because rupture of one of these catheters while in use might cause air bubbles or dangerous fluids to leak into the blood stream resulting in death or serious injury, the catheter sidewalls had to be made thick enough to insure safety and reliability. This was especially important where the catheter was intended to carry fluid under pressure. Furthermore, such thick-walled catheter lumens are not readily inflatable under fluid pressure nor readily collapsible under vacuum, thereby complicating the process of inserting or withdrawing these devices.
With a conventional balloon dilatation catheter used, for example, for an angioplasty procedure, a relatively narrow cross-sectional catheter opening due to the relatively thick catheter sidewalls might be a nuisance but generally would not completely defeat the purpose of such a catheter. Such a device would still generally function as long as sufficient fluid could gradually be transferred through the catheter shaft in order to inflate the balloon and thereby dilate the blood vessel. By contrast, for a heat transfer catheter, the inability to establish and maintain a relatively high fluid flow rate through the catheter would completely defeat the purpose of continuously transferring controlled amounts of thermal energy to or away from remote internal body locations. A slow or uneven flow of heat transfer fluid through the catheter lumen would be unable to overcome the continuous heating or cooling effect of the surrounding body tissue along the relatively long length of the catheter. Moreover, if the heat transfer catheter was intended to be used in conjunction with a dilatation balloon, or with a guide wire, or with a medical instrument, a third, a fourth or additional catheter lumens would need to be provided, each defined by its own relatively thick sidewalls, thereby further restricting the already limited open, cross-sectional area.
Still another problem with the conventional thick-walled multi-lumen catheter is that the relatively thick sidewalls act as insulation and reduce heat transfer between any fluids inside and the surrounding body tissue. Yet another problem with the conventional thick-walled multi-lumen catheters is that the thick walls tend to be relatively rigid and thus do not closely conform to the surrounding body canal, thereby further reducing heat transfer.
These and other problems with and limitations of the prior art catheters in connection with heat transfer applications are overcome with the heat transfer catheters of this invention.
OBJECTS OF THE INVENTION
Accordingly, it is a general object of this invention to provide a catheter apparatus suitable for heat transfer applications inside a living body together with methods for making and using such apparatus.
A principal object of this invention is to provide a heat transfer catheter with fluid lumens having at least in part very thin, high strength sidewalls that are readily inflatable under fluid pressure and readily collapsible under vacuum.
It is also an object of this invention to provide a heat transfer catheter having fluid lumens with very thin, high strength sidewalls that have high heat transfer properties.
A further object of this invention is to provide a heat transfer catheter having fluid lumens with very thin, high strength sidewalls that, when inflated under fluid pressure, closely conform to the geometry of the surrounding body cavity.
A specific object of this invention is to provide a catheter apparatus capable of continuously transferring controlled amounts of thermal energy to or away from adjacent internal body locations that are relatively distant from the point of entry of the catheter into the body over an extended period of time.
Still another specific object of this invention is to provide a heat transfer balloon dilatation catheter capable of dilating a remote internal body location while simultaneously delivering controlled amounts of thermal energy to or withdrawing controlled amounts of thermal energy from an adjacent body location.
Yet another specific object of this invention is to provide a heat transfer catheter for enclosing a diagnostic or therapeutic instrument while simultaneously transferring controlled amounts of thermal energy to or away from all or a portion of the instrument.
These and other objects and advantages of this invention will be better understood from the following description, which is to be read together with the accompanying drawings.
SUMMARY OF THE INVENTION
The heat transfer catheter apparatus of the present invention comprises very thin-walled, high strength thermoplastic tubular material defining a plurality of lumens, at least two of which are adjacent and readily inflatable under fluid pressure and readily collapsible under vacuum. Fluid connection means are provided at or proximate to the distal ends of the two adjacent lumens to define a closed loop fluid containment and circulation system whereby heat transfer fluid from a first, inlet lumen is passed directly to a second, outlet lumen such that a continuous flow of heat transfer fluid through the two lumens can be established and maintained. In one specific embodiment of the present invention, the heat transfer catheter apparatus further comprises a heat transfer fluid, e.g., a cryogenic fluid, inside said inlet and outlet lumens, said fluid being maintained at a substantially constant temperature which is different from normal body temperature. For example, the heat transfer fluid may be at a temperature at least 10° C. different from that of the rest of the subject body. Another specific embodiment of the present invention comprises the step of monitoring the fluid temperature going into said inlet lumen and coming out of said outlet lumen. This embodiment may also comprise the step of adjusting the fluid flow rate through said catheter apparatus so that the fluid coming out of said outlet lumen is at substantially the same temperature as the fluid going into said inlet lumen. Using this method, the temperature of the fluid coming out of said outlet lumen may be maintained within 1° C. of the temperature of the fluid going into said inlet lumen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic longitudinal sectional view of a heat transfer catheter apparatus according to one embodiment of the invention.
FIG. 2 is a cross-sectional view of the catheter apparatus of FIG. 1 along the line 2 — 2 .
FIG. 3 is a schematic longitudinal sectional view of a heat transfer balloon dilatation catheter apparatus according to another embodiment of the invention.
FIG. 4 is an isometric view of a heat transfer balloon dilatation catheter apparatus similar to FIG. 3 but also comprising three straight, perimetrical lumens adjacent to the balloon wall.
FIG. 5 is a cross-sectional view of the catheter apparatus of FIG. 4 along the line 5 — 5 .
FIG. 6 is an isometric view of a heat transfer balloon dilatation catheter apparatus similar to FIG. 3 but also comprising a helical, perimetrical lumen having pin holes for delivering fluid to a body cavity.
FIG. 7 is a cross-sectional view of the balloon portion of another type of multi-lumen heat transfer balloon dilatation catheter apparatus according to another embodiment of this invention.
FIG. 8 is a cross-sectional view of the balloon portion of still another type of multi-lumen heat transfer balloon dilatation catheter apparatus according to the present invention.
FIG. 9 is a schematic, isometric, partial cross-sectional view of a heat transfer catheter according to still another embodiment of the invention.
FIG. 10 is a schematic cross-sectional view of a heat transfer catheter according to yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In each of the drawings, as described below, it should be understood that the wall thicknesses of the catheter and balloon lumens have been greatly exaggerated relative to other elements and to other dimensions for purposes of illustration.
FIG. 1 shows a schematic longitudinal sectional view of a heat transfer catheter apparatus 10 according to the present invention comprising a substantially concentric, coaxial configuration of multiple lumens or channels. The concentric, coaxial arrangement of the multiple lumens can be better understood by reference to FIG. 2 , a cross-sectional view taken along the line 2 — 2 of FIG. 1 . Returning to FIG. 1 , a first, inner catheter tube 12 defines a central conduit 11 receiving a guide wire 13 . Catheter tube 12 may be of conventional, thick-walled construction or, alternatively, comprise very thin sidewalls. For purposes of this invention, the terms “very thin walls” or “very thin-walled” refer to elongated sleeves or catheters having sidewalls ranging in thickness from about 0.0002 inches up to about 0.002 inches, and, in some preferred embodiments, a wall thickness not exceeding 0.0009 inches. By comparison, the conventional “thick-walled” constructions of prior art multi-lumen catheters typically range in thickness from about 0.003 to about 0.010 inches or more. For purposes of this invention, the term “elongated” refers to catheter apparatus or to sleeves having an overall length-to diameter ratio of about 25:1 or greater. In the embodiment of FIG. 1 , if catheter tube 12 is of conventional construction, tube 12 may provide sufficient rigidity by itself for insertion of the apparatus into a body canal or passageway. Alternatively, if inner catheter tube 12 is of very thin-walled construction, wire guide 13 , previously positioned using a guide catheter or other conventional manner, may be needed in order to facilitate threading the catheter apparatus through a blood vessel or similarly narrow passageway. Inner catheter tube 12 may be of single or multi-lumen construction depending on the number of channels desired for a particular application. Catheter tube 12 may be configured open at both ends, for example to fit over a wire guide 13 , and to act as a channel to inject or drain fluid, or to contain a diagnostic or therapeutic device. Alternatively, tube 12 can also be sealed at its distal end or configured in other advantageous ways.
Surrounding at least a portion of the length of inner catheter tube 12 is a very thin-walled, inflatable and collapsible, elongated inner sleeve 14 which may be, but need not be, at least partially sealed at its distal end to the outer surface of tube 12 so as to create a second or intermediate lumen 16 comprising an annual region with a donut-like cross section surrounding catheter tube 12 . The annular configuration of lumen 16 can be better understood by reference to FIG. 2 . For example, if tube 12 has an external diameter of about 0.04 inches, sleeve 14 may comprise biaxially-oriented polyethylene terephthalate (PET) and have an inner diameter of about 0.087 inches and a sidewall thickness of about 0.0005 inches. Surrounding at least a portion of the length of sleeve 14 is a very thin-walled, inflatable and collapsible, elongated outer sleeve 20 which is sealed at its distal end to the outer surface of tube 12 at a point distal from the distal end of sleeve 14 so as to create a third or outer lumen 22 comprising an annular region with a donut-like cross section surrounding sleeve 14 . The annular configuration of lumen 22 can be better understood by reference to FIG. 2 . In the preceding example, sleeve 20 may comprise biaxially-oriented PET and have an inner diameter of about 0.125 inches and a sidewall thickness of about 0.00065 inches. Fluid connection means 18 , in this case comprising an opening between the open distal end of sleeve 14 and the inner wall of sleeve 20 , places the distal end of lumen 16 in direct fluid communication with the distal end of lumen 22 . Alternatively, the fluid connection means may comprise one or a plurality of apertures in the common wall means (i.e. in sleeve 14 ) separating lumens 16 and 22 . In the foregoing example, the total cross-sectional area available for inlet and outlet fluid flow, as seen in FIG. 2 , represents approximately 87% of the available cross-sectional area of the body canal in which the catheter apparatus is positioned. For the heat transfer catheters of this invention, at least about 60%, and preferably greater than about 80% of the available cross-sectional area of the body canal should be available for fluid flow. Although lumens 16 and 22 are shown in FIG. 1 as single lumens, it should be appreciated that one or both of these lumens may be fabricated as a multi-lumen structure, but obviously with some small associated loss of available fluid flow area because of additional wall means.
Catheter apparatus 10 as shown in FIG. 1 further comprises a first or proximal manifold section 30 and a second or distal manifold section 32 . The distal end of manifold 30 is adapted to sealingly mate with the proximal end of manifold 32 , for example by means of male and female threaded elements, 34 and 36 respectively, in combination with a resilient O-ring 38 . Alternatively, manifolds 30 and 32 may be adhesively bonded to one another. Male element 34 of manifold 30 further comprises a centrally-located bore 40 . Manifold 30 also comprises a fluid inlet port 42 connected to a source, such as reservoir 43 , of fluid via a fluid fitting, which may also comprise an inlet valve 41 or other fluid flow control means, and an end seal 44 . End seal 44 of manifold 30 also comprises a centrally-located bore 46 . Bore 46 is sized so as to receive catheter tube 12 . Fluid sealing means (not shown) are provided between the outside of tube 12 and the surface of bore 46 to prevent fluid leakage. Bore 40 is sized so as to receive both tube 12 and sleeve 14 . The proximal end of sleeve 14 comprises fluid sealing means, such as an annular lip or flange 15 projecting radially outward and capable of being bonded or sealed to an inner wall of manifold 30 . Alternatively, the outside of the proximal end of sleeve 14 may be adhesively bonded to the wall of bore 40 .
Manifold 32 further comprises an outlet port 50 , which may comprise an outlet valve 51 or other fluid flow control means, a tapered distal end 52 having a tubular projection 54 , and a centrally-located opening 56 passing through tapered end 52 and projection 54 . Opening 56 is sized so as to receive catheter tube 12 and sleeves 14 and 20 while leaving an open annular region defined by the outside of sleeve 14 and the inside surface of sleeve 20 through which fluid can pass. The outside of the proximal end of sleeve 20 may be adhesively bonded to the wall of opening 56 . Thus, after the distal portion of catheter apparatus 10 is positioned in the body, fresh heat transfer fluid at a desired temperature, ordinarily (but not necessarily) different from normal body temperature, first enters manifold 30 through inlet port 42 (as illustrated by the fluid direction arrows), passes through the interior cavity of manifold 30 into the proximal end of sleeve 14 at lip 15 , then passes through inlet fluid lumen 16 to the distal end of sleeve 14 , then passes directly through fluid connection means 18 into outlet fluid lumen 22 , then passes back through lumen 22 to the proximal end of sleeve 20 , then passes into the interior of manifold 32 from which it exits through exit port 50 . As used herein, the term “inlet fluid lumen” means a passageway or conduit of an elongated catheter through which fluid flow is substantially in a direction from the proximal end toward the distal end. Correspondingly, the term “outlet fluid lumen” means a passageway or conduit of a catheter through which fluid flow is substantially in a direction from the distal end toward the proximal end. The spent heat transfer fluid exiting through port 50 may be recovered and heated or cooled (as necessary), for example with a conventional heating or cooling jacket 45 surrounding fluid reservoir 43 , to restore it to the desired temperature and then recycled back to inlet port 42 .
The heat transfer fluids that are useful in the practice of this invention include both gases and liquids, but are preferably liquid. The fluid may be water or an aqueous solution, for example normal saline, provided the desired heating or cooling temperature is within the liquid range of water, i.e. about 0-100° C. For special applications, particularly for operating temperatures below 0° C. or above 100° C., other fluids, such as the various halogenated hydrocarbons (e.g. “Freon”), may be utilized. Obviously the selected fluid must be one that will be chemically compatible with the material from which the fluid lumens are constructed at the desired operating temperature.
As illustrated in FIG. 1 , manifold sections 30 and 32 may comprise metal, plastic or other suitable materials. Catheter tube 12 , inner sleeve 14 and outer sleeve 20 may comprise the same or different thermoplastic materials. The choice of materials and fabrication techniques may be adapted to meet particular design specifications or to realize particular properties of the completed apparatus. Some of the specific fabrication techniques, material selections, and desirable design features that are within the scope of this invention are presented below for purposes of illustration. Other advantageous variations will be apparent to those skilled in the art, and such obvious variations are also considered to be within the scope of this invention.
With regard to sleeves 14 and 20 , it is preferred that these sleeves be of high tensile strength and able to withstand anticipated internal fluid operating pressures, which, for some applications, may be on the order of about 200 psi and higher, while, at the same time, being sufficiently thin-walled to have good heat transfer properties, to insure good contact with the walls of the internal body cavity during use, and to minimize wasted internal space. These sleeves should also be readily inflatable under fluid pressure and readily collapsible under vacuum to facilitate insertion and removal of the catheter apparatus. To realize these combined objectives, sleeves 14 and 20 should have sidewalls not exceeding a thickness of about 0.002 inches, preferably less than about 0.001 inches, and for some embodiments, less than 0.0009 inches. Sleeves 14 and 20 can be fabricated from an orientable polymeric material, for example using tubing extrusion and blow molding techniques, such as those taught in my U.S. Pat. Nos. 5,411,477 and 5,342,301. Biaxially-oriented PET sleeves can be prepared as thin as 0.0002 inches, for example, while retaining adequate tensile strength to insure against any ruptures while in use. Because thicker walls of biaxially-oriented PET tend to be somewhat rigid, it is preferred that such sleeves for this invention have sidewall thicknesses ranging from about 0.0002-0.0009 inches. In an alternative embodiment for certain applications, sleeves 14 and/or 20 may be fabricated from weaker but more flexible materials. For example, polyurethane sleeves may have sidewalls as thick as about 0.005 inches while still retaining the necessary flexibility for expansion, collapse, and conformity with the walls of the internal body cavity while in use. It will be understood that, for any given sleeve material, thinner sleeves will have better heat transfer properties than thicker sleeves.
For most applications, including all dilatation applications, it is preferred that fluid-carrying sleeves 14 and 20 be relatively inelastic. Fabrication of sleeves 14 and 20 from biaxially-oriented PET, as discussed above for example, would yield very thin-walled, high strength, relatively inelastic sleeves. Any polymeric material capable of being oriented in at least one direction with resultant enhancement of mechanical properties, particularly strength, could be used to fabricate one or more of the sleeves and catheters of this invention. Depending on the specific apparatus construction and intended application, such materials include PET, nylon, crosslinked polyethylene and ethylene copolymers, urethanes, vinyls, and Teflon, among others. In some applications, it may be preferred to fabricate outer sleeve 20 , or both sleeves 14 and 20 from an elastomeric material. One such application would be where only relatively low fluid pressures are needed, for example where the catheter apparatus does not include a dilatation balloon and is not expected to be used in a dilatation procedure. Another such application would be where variations in internal anatomy would prevent an inelastic outer sleeve from making good heat transfer contact with the walls of the internal cavity or passageway.
If sleeves 14 and 20 are fabricated from PET, in addition to containing a heat transfer fluid in accordance with this invention these sleeves would also be capable of transmitting microwave energy, Nd:YAG laser energy, UV laser energy, and others from the proximal to the distal end of the apparatus. Also, if the fluid-carrying sleeves are fabricated from a suitable material, such as biaxially-oriented PET or PTFE (Teflon), the catheter apparatus would be capable of circulating cryogenic fluids for selective freezing of tissue such as cancerous tumors. In this case, for certain applications, it may be necessary to utilize multiple lumens so as to combine heating of the catheter via this technology along most of the length of the catheter while having the cryogenic freezing occur only at a specific desired location at or near the distal end of the catheter apparatus. The heating would prevent the entire catheter from freezing, thereby damaging tissue areas that should not be treated. For example, multiple lumens inside catheter tube 12 could be used to circulate a cryogenic fluid while sleeves 14 and 20 contained a heating fluid to insulate adjacent tissue along the length of the catheter except for the distal end beyond the end of sleeve 20 . In still another embodiment, the distal end of tube 12 may communicate with a balloon element, which could then also provide heating or cooling effects. Simultaneous selective heating and cooling can also similarly be provided with the catheter apparatus according to this invention; or, differential heating or cooling can be provided where, for example, one side of the catheter is hotter or cooler than the other side in order to provide for treatment of asymmetric anatomical features. Alternative embodiments of the catheter apparatus, as hereinafter described, may also be adapted for such differential heating and/or cooling applications.
In still another embodiment of this invention, the diameters and wall thicknesses of tube 12 and of sleeves 14 and 20 may be selected such that lumens 16 and 22 have substantially equal cross-sectional areas for fluid flow. Alternatively, by adjusting the diameters of one or more of tube 12 , sleeve 14 and sleeve 20 , the cross-sectional areas of annular lumens 16 and 22 may be varied to create different pressure gradients and fluid flow rates. In another fabrication variation, sleeves 14 and 20 may be formed so as to have substantially constant cross-sectional diameters along their respective lengths at constant fluid pressure. Alternatively, one or both of sleeves 14 and 20 may be formed so as to have varying cross-sectional diameters along their lengths in order to generate particular flow patterns, for example to cause turbulent fluid flow at a desired location for purposes of increased heat transfer.
FIG. 3 is a schematic, cross-sectional view of an alternative embodiment of a heat transfer catheter in accordance with this invention. In FIG. 3 , catheter apparatus 60 comprises a multi-lumen balloon dilatation catheter comprising a first or inner sleeve 62 , defining an open space or inner lumen 64 , and a second or outer sleeve 66 surrounding inner sleeve 62 so as to create an outer annular lumen 68 . Inner sleeve 62 is formed open at its distal end and spaced from the inner wall of sleeve 66 so as to create a fluid connection 70 . Outer sleeve 66 is formed closed at its distal end. The closed distal end of sleeve 66 is at a point that is distal from the open distal end of sleeve 62 so that fluid may pass through fluid connection means 70 from fluid inlet lumen 64 into fluid outlet lumen 68 .
Proximate to its distal end, outer sleeve 66 comprises a dilatation balloon segment 72 . Balloon segment 72 is preferably of very thin-wall, high strength construction, substantially inelastic, and readily inflatable under fluid pressure and readily collapsible under vacuum. In a preferred embodiment of this variant, at least sleeve 66 and balloon segment 72 comprise a unitary, integral and seamless unit wherein said sleeve portion and said balloon segment are integrally formed in accordance with the teachings of my U.S. Pat. No. 5,411,477. In this embodiment of the invention, fresh heat transfer fluid is introduced into the proximal end of inner lumen 64 , passes through lumen 64 and fluid passage means 70 directly into outer lumen 68 , through the interior of balloon segment 72 , and then back along lumen 68 to the proximal end of the apparatus where the spent fluid is withdrawn. During use, fluid flow control means, such as inlet and outlet valves in conjunction with a manifold structure as shown in FIG. 1 , at the proximal ends of lumens 64 and 68 may be used to maintain fluid pressure inside lumens 64 and 68 at a level that is sufficient to fully inflate balloon segment 72 . Alternatively, a restriction can be incorporated into the manifold so as to create pressure in the lumens.
The heat transfer balloon dilatation catheter apparatus of FIG. 3 may be utilized in several different ways. In one embodiment, lumens 64 and 68 may be partially inflated with fluid in order to provide the stiffness needed to insert the catheter. Once the apparatus is properly positioned, the fluid pressure may be increased so as to fully inflate the dilatation balloon segment 72 . Alternatively, a separate rod or hollow tube 74 , as illustrated in FIG. 3 , can be inserted through inner lumen 64 to provide stiffness. Tube 74 may be a solid rod or a hollow tube defining another lumen 76 . Tube 74 may also comprise an elongated diagnostic or therapeutic device that is either permanently attached to the catheter apparatus or is removable, so that the catheter apparatus can be disposable and the medical instrument reusable or vice versa. Examples of instruments that could be utilized in such a combination catheter apparatus include microwave antennas, lasers, ultrasound probes, induction coils, and electric heating elements.
The requisite properties of sleeves 62 and 66 in FIG. 3 , the materials from which these sleeves are prepared, and the sleeve fabrication techniques are similar to those discussed above for sleeves 14 and 20 respectively in FIG. 1 . Thus, sleeves 62 and 66 , including balloon segment 72 , must have sufficient strength to withstand anticipated internal fluid operating pressures while, at the same time, being sufficiently thin-walled to have good heat transfer properties, to insure good contact with the walls of the internal body cavity during use, and to minimize wasted internal space. These sleeves should also be readily inflatable under fluid pressure and readily collapsible under vacuum. To realize these combined objectives, sleeves 62 and 66 , including balloon segment 72 , generally have sidewalls not exceeding a thickness of about 0.002 inches. Similar to sleeves 14 and 20 in FIG. 1 , sleeves 62 and 66 in FIG. 3 may be fabricated from an orientable polymeric material, for example using tubing extrusion and blow molding techniques. For this embodiment of the invention, sleeves 62 and 66 and, particularly, balloon segment 72 , should be relatively inelastic such that, when fully inflated and undeformed, balloon segment 72 dilates to a predetermined, repeatable size and shape. Biaxially-oriented PET sleeves having sidewall thicknesses of about 0.0002-0.0009 inches are a particularly advantageous embodiment of this version of the invention.
The heat transfer balloon dilatation catheter apparatus as described above may further comprise one or a plurality of adjacent lumens located externally of the maximum realizable dimension of the inelastic balloon segment 72 and adjacent to the wall of the balloon when the balloon is fully inflated and undeformed. In this embodiment, the balloon segment shares with each said adjacent, external lumen a single-layer, integrally formed wall section comprising a portion of the balloon wall and separating the interior of the balloon from the interior of the adjacent, external lumen. The balloon comprises a very thin, flexible, high strength, substantially inelastic material having a wall thickness of less than about 0.0015 inches, preferably less than about 0.0009 inches. The preparation and use of such multi-lumen balloon dilatation catheters is taught in my U.S. Pat. No. 5,342,301.
FIGS. 4-6 illustrate one set of embodiments of a heat transfer, multi-lumen balloon dilation catheter apparatus according to the present invention. FIG. 4 shows a previously-formed heat transfer balloon dilatation catheter apparatus 230 , generally comparable to apparatus 60 of FIG. 3 , comprising an outer sleeve 232 (best seen in FIG. 5 ) having a closed distal end 233 and a concentric, coaxial inner sleeve 234 . This structure is clearly evident in FIG. 5 , a cross-sectional view along the line 5 — 5 of FIG. 4 . Outer sleeve 232 comprises a balloon segment 236 having conical or tapered ends 238 and 240 . Thus, in one embodiment in accordance with this invention, the catheter apparatus of FIG. 4 can be operated as a heat transfer catheter comparable to FIG. 3 , wherein heat transfer fluid enters through the lumen defined by inner sleeve 234 , dilates balloon segment 236 , and exits through the annular lumen defined between sleeves 232 and 234 , with fluid flow controlled by inlet and outlet valves in conjunction with a manifold structure as shown in FIG. 1 . Other embodiments utilizing the apparatus of FIG. 4 , as discussed below, are also contemplated, however. In accordance with the technique described in U.S. Pat. No. 5,342,301, mandrels or forming wires may be positioned along the external surface of outer sleeve 232 and a tube 250 (best seen in FIG. 5 ) of a heat-shrinkable thermoplastic thereafter shrunk around sleeve 232 so as to create one or more of adjacent, external lumens 242 , 244 , and 246 , each integrally formed with a portion of sleeve 232 .
Fluid flow connection means, for example one or more apertures, may be provided in the integrally formed wall means that separates the interior of balloon segment 236 and one or more of the adjacent, external lumens 242 , 244 and 246 . In this embodiment, instead of having coaxial inner sleeve 234 , fluid may be supplied to balloon segment 236 through sleeve 232 and withdrawn through an externally-extending adjacent, external lumen such as lumen 242 . As seen in FIG. 4 , external, adjacent lumen 242 can be formed so as to run the entire length of sleeve 232 , including balloon segment 236 and conical ends 238 and 240 . Thus, in still another embodiment of this invention, an apparatus similar to that shown in FIG. 4 but having two perimetrical lumens like lumen 242 running the entire length of sleeve 232 could be used to deliver heat transfer fluid to a body location distal of balloon segment 236 . The flow of heat transfer fluid, in through one of said perimetrical lumens and out through the other, would not be significantly interrupted even during dilatation of balloon segment 236 . Similarly, and for other applications, external, adjacent lumen 244 can be formed so as to run from one end of the middle or working section of balloon 236 to the other. Similarly, external, adjacent lumen 246 can be formed so as to begin and end within the working section of balloon 236 . By proper selection of the forming wires, external, adjacent lumens can be created of the same or different diameters, of uniform or non-uniform cross-section, and of circular or other cross-sectional shape, as desired for particular applications. Employing a similar preparation technique, a heat transfer balloon dilatation catheter apparatus can be prepared as shown in FIG. 6 wherein an external, adjacent lumen 252 runs in a helical pattern around the outside wall of balloon 236 . Helical lumen 252 may comprise, in one embodiment, a plurality of pinholes 254 along its length to precisely deliver medication or other fluids to select body locations.
FIGS. 7 and 8 illustrate alternative embodiments of a heat transfer, multi-lumen balloon dilatation catheter apparatus according to the present invention. The preparation and use of multi-lumen balloons having cross-sectional configurations similar to those shown in FIGS. 7 and 8 is also taught in my U.S. Pat. No. 5,342,301. Thus, the nine-lumen balloon structure of FIG. 7 is prepared either by heat-shrinking a thermoplastic sleeve over the four-lobe interior structure (which, in turn, is made by blow molding a five-lumen extruded preform) or by blow molding a five-lumen extruded preform inside a thermoplastic sleeve.
FIG. 7 shows a multi-lumen balloon 122 in accordance with this alternative embodiment of the present invention. In this design, the catheter shaft 124 is of a conventional design, except that it does not have to be provided with lumens for allowing for fluid flow when the balloon is inflated. Instead the balloon is formed as a multi-lumen balloon in accordance with my U.S. Pat. No. 5,342,301 for providing the necessary fluid flow, and for providing the necessary inflation so as to achieve dilatation of a selected body passageway. As seen in FIG. 7 , center lumen 132 receives the catheter shaft 124 so that the balloon can be secured in place with a suitable adhesive to the shaft. At least four lumens 126 , 127 , 128 and 130 are radially spaced around center lumen 132 for receiving the pressurized fluid for inflating each of these lumens so as to achieve dilatation. The lumens 126 , 127 , 128 and 130 , must be closed or connected and be adapted to be in fluid communication with a source of pressurized fluid. Lumens 134 , 135 , 136 and 138 , are formed within the spaces between lumens 126 , 127 , 128 and 130 , and the corresponding wall sections 140 , 143 , 142 and 144 , when lumens 126 , 127 , 128 and 130 are inflated.
In FIG. 7 , one or more of lumens 126 , 127 , 128 and 130 , for example, could be utilized as inlet lumens for heat transfer fluid, and one or more of lumens 134 , 135 , 136 and 138 could be utilized as outlet lumens for heat transfer fluid, by providing fluid connection means between adjacent inlet and outlet lumens. For example, lumen 126 could be provided with apertures in its sidewall to permit fluid flow into one or both of adjacent lumens 134 and 138 . Correspondingly, lumen 130 could be provided with apertures in its sidewall to permit fluid flow into one or both of adjacent lumens 135 and 136 . In this example, inlet lumen 126 and outlet lumens 134 and 138 could carry heat transfer fluid at a first temperature, while inlet lumen 130 and outlet lumens 135 and 136 could carry heat transfer fluid at a second, different temperature. Those lumens not being utilized to circulate heat transfer fluid, such as central lumen 132 and side lumens 127 and 128 in the above example, could be utilized to enclose a medical instrument, a guide wire, or the like, or to provide fluid passageways for medicine delivery, fluid drainage, or perfusion applications. Although FIG. 7 illustrates a multi-lumen dilatation balloon having nine lumens, at least two of which must be interconnected to provide fluid flow in accordance with the present invention, it will be understood that similar preparation techniques could be used to prepare similar multi-lumen balloon structures having more or fewer lumens than nine.
The structure of FIG. 8 is prepared by blow molding a nine-lumen extruded preform of appropriate starting geometry, also as described in U.S. Pat. No. 5,342,301. Similar to FIG. 7 , FIG. 8 illustrates a nine-lumen balloon structure in which one or more of lumens 426 , 427 , 428 and 430 , for example, could be utilized as inlet lumens for heat transfer fluid, and one or more of lumens 434 , 435 , 436 and 438 could be utilized as outlet lumens for heat transfer fluid, by providing fluid connection means between adjacent inlet and outlet lumens. In FIG. 8 , reference numerals 422 , 424 , 432 , 440 , 442 , 443 and 444 refer respectively to the comparable structural elements as in FIG. 7 , namely reference numerals 422 / 122 (multi-lumen balloon); 424 / 124 (catheter shaft); 432 / 132 (center lumen); and 440 / 140 , 442 / 142 , 443 / 143 , and 444 / 144 (wall sections). For example, lumen 427 could be provided with apertures in its sidewall to permit fluid flow into one or both of adjacent lumens 434 and 435 . Correspondingly, lumen 428 could be provided with apertures in its sidewall to permit fluid flow into one or both of adjacent lumens 436 and 438 . In this example, inlet lumen 427 and outlet lumens 434 and 435 could carry heat transfer fluid at a first temperature, while inlet lumen 428 and outlet lumens 436 and 438 could carry heat transfer fluid at a second, different temperature. As discussed above with respect to FIG. 7 , those lumens not being utilized to circulate heat transfer could be utilized for other applications. It will be understood that similar preparation techniques could be used to prepare similar multi-lumen balloon structures having more or fewer lumens than nine.
FIG. 9 illustrates yet another embodiment of this invention. In FIG. 9 , catheter apparatus 80 comprises two concentric, coaxial lumens consisting of an inner inlet lumen and an outer outlet lumen. The inner inlet lumen 82 defined by inner sleeve 84 is surrounded by a closed-end outer sleeve 86 of larger diameter than inner sleeve 84 thereby defining an annular outlet lumen 88 having a donut-like cross section. Inner sleeve 84 includes fluid communication means, such as multiple apertures or side holes 90 which permit fluid to pass directly from inlet lumen 82 to outlet lumen 88 at or near the distal end of inlet lumen 82 . The proximal end of inlet lumen 82 is coupled to fluid inlet means 83 , for example a one-way valve. Correspondingly, the proximal end of outlet lumen 88 is coupled to fluid outlet means 89 , for example a one-way valve. Housing means 85 may be provided to facilitate coupling the inlet and outlet lumens to their respective inlet and outlet valves.
Similar to the embodiment shown in FIG. 3 , the catheter apparatus of FIG. 9 may be filled with fluid and pressurized in order to stiffen it sufficiently to facilitate insertion or, alternatively, a solid rod or hollow tube (not shown) can be inserted into one of the lumens to provide the necessary stiffness. Instead of a rod or tube, an elongated diagnostic or therapeutic device may be used to provide stiffness. Such device may either be permanently attached to the catheter apparatus or it may be removable, so that the catheter apparatus can be disposable and the medical device reusable or vice versa.
FIGS. 1-6 and 9 as discussed above illustrate embodiments of this invention in which the heat transfer fluid inlet and outlet lumens are concentric and coaxial. This configuration is relatively easy to manufacture and generally permits maximum fluid flow for any given external catheter diameter because a single-layer wall means (for example, sleeve 14 in FIGS. 1 and 2 , sleeve 62 in FIG. 3 , sleeve 234 in FIG. 5 , and sleeve 84 in FIG. 9 ) can serve as both the outer wall of an inner inlet lumen and as the inner wall of an outer, annular-shaped outlet lumen. Other configurations of inlet and outlet lumens, however, are also within the scope of this invention. FIGS. 7 and 8 illustrate two embodiments wherein the inlet and outlet lumens are not in a concentric, coaxial configuration. Another such alternative configuration is illustrated in FIG. 10 .
FIG. 10 is a schematic cross-sectional view of a different lumen configuration for another heat transfer catheter 100 in accordance with this invention. In FIG. 10 , outer sleeve 102 surrounds and encloses two inner sleeves 104 and 106 of smaller diameter which define respectively lumens 108 and 110 . Also shown in FIG. 10 , enclosed within outer sleeve 102 but external of lumens 108 and 110 , is a central longitudinal member 112 which may, in alternative embodiments, comprise a rod, a hollow tube, or a diagnostic or therapeutic instrument, or a combination of one or more. If, as illustrated in FIG. 10 , sleeves 104 and 106 and member 112 are of such size and geometry as to not fill all of the interior space enclosed by outer sleeve 102 , upon fluid inflation an irregularly shaped lumen 114 would also be created inside sleeve 102 . Thus, in this embodiment, lumens 108 and 110 could be utilized as fluid inlet lumens for introducing heat transfer fluid to catheter apparatus 100 , and lumen 114 utilized as the fluid outlet lumen. Fluid connection means (not shown), such as holes or apertures in sleeves 104 and 106 , are provided to establish a flow of the heat exchange fluid from inlet lumens 108 and 110 to outlet lumen 114 .
The catheter configuration illustrated in FIG. 10 facilitates a number of advantageous variations on the basic invention. For example, the catheter apparatus 100 of FIG. 10 can, similar to the embodiments of FIGS. 7 and 8 , provide heat transfer fluid at two different temperatures, for example one for selective heating, the other for selective cooling. Different fluid flow rates can also be established in inlet lumens 108 and 110 . Inner sleeves 104 and 106 may be either of the same or different diameters, wall thicknesses, and materials. By making one of the inner sleeves of a larger diameter than the other, upon fluid inflation member 112 will be displaced off-center and moved closer to one side of the inner wall of sleeve 102 than the other side. This embodiment may be useful where member 112 is a medical instrument. A similar result could be achieved by selectively inflating only one of the two inner sleeves 104 and 106 .
It will be understood that a catheter apparatus according to this invention as illustrated in FIG. 10 could be prepared with only one inner sleeve (i.e. only one fluid inlet lumen) or, alternatively, with three, four or more inner sleeves instead of the two shown. It will also be understood that for any of the catheter apparatuses within the scope of this invention the heat transfer inlet and outlet lumens can be configured to run substantially the entire working length of the catheter or to occupy only a discrete, predetermined portion of the catheter. For example, the heat transfer inlet and outlet lumens may commence at the point where the catheter enters the body and terminate at a location intermediate of the distal end of the catheter. Alternatively, the heat transfer inlet and outlet lumens may be defined by conventional “thick-walled” sidewalls along a proximal section of the catheter, and defined by very thin sidewalls of about 0.0002-0.002 inches thickness only along a distal section of the catheter. In this construction, heat transfer would be minimized along the proximal, thick-walled section of the catheter and maximized at the thin-walled distal end.
Since certain changes may be made in the above-described apparatuses and processes without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description shall be interpreted in an illustrative and not in a limiting sense. | Heat transfer catheter apparatus and methods of making and using same are disclosed wherein a fluid connection is provided between the distal portions of two adjacent, thin-walled, high strength fluid lumens to define a closed loop fluid circulation system capable of controlled delivery of thermal energy to or withdrawal of thermal energy from remote internal body locations. | 0 |
This is a division, of application Ser. No. 806,951, filed Dec. 12, 1991, now U.S. Pat. No. 5,161,725, which is a continuation of application Ser. No. 479,318, filed Feb. 13, 1990, abandoned, both of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The invention relates generally to surgical staplers. More specifically, the invention relates to skin staplers used during surgery Most specifically, the invention relates to surgical skin staplers having rotating heads.
BACKGROUND OF THE INVENTION
In recent years, the use of skin staplers has become one of the preferred methods of wound closure. Skin staplers rapidly and accurately close surgical wounds. Effective tissue eversion during skin stapling allows for rapid healing, and reduces the possibility of infection.
Nonetheless, as skin staplers have improved, so has the need for increased reliability and various new and unforeseen characteristics. Thus, it is greatly desirable to provide skin staplers which contain reliable staple feeding mechanisms. Previous staple feeding mechanisms have either been bulky or complex, or even quite unreliable. In order to form a more accurate skin stapler, the need exists for a reliable feeding mechanism able to fit within a staple cartridge or track, and demonstrate a thin profile in order to provide accurate, yet visible staple placement onto a surgical site.
In addition, previous systems have contained unreliable drive mechanisms. Previous systems must proceed completely along a single stroke to be fired. Not completely firing this type of stapler has previously increased the likelihood of jamming, causing delay and unreliability in the system. Of course, even if one disregards the possibility of the stapler jamming, if no provision is made for stopping the firing sequence, it is possible to lose accurate control and placement of the surgical staple.
In many staplers, feel of the mechanism is quite important. If the surgeon is able to "feel" a staple as it is being driven into the skin, the surgeon can properly place the staples and close the wound. Extremely important to such "feel" is the completion of the driving stroke. Inadvertently, the triggering mechanism goes through a rapid change in the force encountered at the stapling site. This may cause the trigger mechanism to "jump" in the surgeon's hand, due to recoil from these forces. This affects the feel to the surgeon, who desires a very smooth stroke in the stapler.
In addition, the track in which the staples are formed has been very difficult to control in manufacturing processes. This is due, in part, to the very tight manufacturing tolerances through which the staple and cartridge must be held to prevent malforming of the staple. In some staplers, especially those where the preformed staple is larger in width than its final formed shape, it is difficult to control the formation of the staple while allowing for accurate placement. Thus, it is desirable to provide a system where the staple itself enhances its own accurate placement at the forming site and, ultimately, in closing the wound.
Finally, when forming the staple, what is most necessary is repeatably creating a properly shaped staple. This allows the surgeon to position and properly place the staple on the skin. This creates the proper environment on the skin for quick and safe wound healing.
Furthermore, these desirable features of a skin stapler should be incorporated into a skin stapler with a rotating head. The rotating head concept allows the user to place the staple at the wound site, and then to examine the site before closure, without raising the stapler from the surface of the skin. In this way, the user is able to maintain contact throughout closure.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a skin stapler with a rotating head where the staples are reliably transferred from the cartridge track in which the staples are maintained to the staple forming site.
It is another object of the invention to provide a stapler where the user can relax the grip on the stapler driving mechanism without potentially harming the formation of the staple, or jamming the staples in the staple forming track.
It is yet another object of the invention to provide a smooth and accurate placement and closure of the staple without "snap" felt in the trigger mechanism.
It is still another object of the invention to allow ease of manufacture while ensuring accurate placement and positioning of staples on the staple former and in the skin.
It is yet another object of the invention to center the staples on an anvil surface prior to and during staple forming to achieve a consistently more precise formed skin staple.
It is finally an object of the invention to incorporate all of these characteristics into a stapler containing a rotating staple head, whereby staple forming precision, reliable ease of function, and accuracy are embodied in a stapler having many versatile wound closure capabilities.
These and other objects of the invention are accomplished in a surgical stapler with a rotating head where the staple transfer mechanism contains a lifter spring which provides the force necessary to lift the staple across the stapler head from a feeding track into a parallel staple forming track. This lifter mechanism supports the staple crown and legs to properly maintain the staple in position before the forming stroke. The lifter mechanism also contains a tab which maintains the staple position on the staple lifter until the staple is moved to the staple forming track.
At the opposite end of the stapler, the driving mechanism contains a ratcheting means which allows the user to relax the stroke during forming, and yet prevent jamming. A buffer mechanism provides a resistive force to the driver mechanism, thus spreading staple forming forces and minimizing any "snap" during the final stages of staple forming.
Finally, the stapler has a wing-shaped forming mechanism which closely parallels the winged shape profile of the staples. This former mechanism centers the staple on the anvil and ensures reliable and consistent staple formation and placement on the skin. A reduced anvil size causes the staple to maintain an accurate and Precise shape during forming.
These objects of the invention will be better understood by the following Detailed Description of the Drawings taken in conjunction with the Detailed Description of the Invention.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the rotating head skin stapler of this invention;
FIG. 2 is an exploded perspective view showing the replaceable staple cartridge removed from the rotating head;
FIG. 3 is a partial perspective view showing the rotating head in one possible orientation;
FIG. 4 is a partial perspective view of the rotating head in another possible orientation;
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 2;
FIG. 6 is a view similar to FIG. 5 after compressing the handle and trigger;
FIG. 7 is a fragmentary view in cross-section of the trigger mechanism of the invention;
FIG. 8 is a fragmentary view of the buffer mechanism;
FIG. 9 is a plan view of the drive block and drive train rotating mechanism;
FIG. 10 is a perspective view of the drive block and drive train mechanism;
FIG. 11 is a partial top plan view of the rotating head skin stapler;
FIG. 12 is a partial bottom plan view of the rotating head skin stapler;
FIG. 13 is a cross-sectional view taken along line 13--13 of FIG. 11;
FIG. 14 is a partial perspective view showing a formed staple which released from the distal end of the staple cartridge;
FIG. 15 is a partial top plan view of the distal portion of the staple cartridge with the top of the cartridge partially broken away for clarity;
FIG. 16 is a cross-sectional view taken along line 16--16 of FIG. 15;
FIG. 17 is a partial bottom plan view of the staple cartridge just after forming the staple;
FIG. 18 is a cross-sectional view taken along line 18--18 of FIG. 17; and
FIG. 19 is an exploded perspective view of the staple cartridge of this invention.
DETAILED DESCRIPTION OF THE INVENTION
As seen in FIGS. 1 through 4, the rotating head skin stapler 10 contains a base 20 housing a drive mechanism which is activated by a trigger 40 squeezed within handle 50. The drive mechanism contained in the base 20 causes staples to be fired from cartridge 70. The rotating head 60 allows orientation of the cartridge 70 in any angular direction in relation to base 20 on the wound surface to be closed, as best seen in FIGS. 3 and 4.
Various aspects of the rotating head skin stapler 10 will now be explained Intrinsic to the rotating head skin stapler 10 is rotating head 60. This rotating head 60 is attached to the base 20 by means of collar 64 enmeshed within holding cylinder 21 as better seen in FIGS. 5 and 6. Drive train 66 is rotatably connected at its proximal end to drive block 44 and at its distal end contacts former 76 within the plane of cartridge 70. Drive train 66 fits axially into collar 64 on rotating head 60. Drive train 66 is generally flat in shape, and constantly enmeshed between cartridge 70 and rotating head 60, as will be explained later. Because drive train 66 and cartridge 70 are fitted into the center of rotating head 60, and rotate about drive block 44, during rotation they maintain positional relationship with base 20, so that the orientation of cartridge 70 is optional to the user. For instance, as seen in FIG. 4, cartridge 70 has been rotated to expose head plate 69.
At its proximal end, drive train 66 is rotatably engaged with drive block 44. This is accomplished by inserting notched perforations 67 at the proximal end of drive train 66 around circular node 47 of drive block 44, as better seen in FIGS. 9 and 10. Thus, the notched perforations 67 are free to rotate about circular node 47 to allow drive train 66 to rotate about drive block 44, as seen in FIGS. 5 and 6. In this way, wherever rotating head 60 is oriented with drive train 66 contained therein, drive train 66 remains attached to drive block 44, and transfers force through the rotating head 60 and cartridge 70 combination.
For operation of the stapler, it is necessary for drive train 66 to have force imparted on it by drive link or drive block 44. As drive train 66 is rotatably attached by notched perforations 67 onto the drive block circular node 47, only force exerted along the same axis as drive train 66 will be imparted from drive block 44.
As better seen in the enlarged and various views of the interior of base 20 in FIGS. 5, 6, 7, 8, 9 and 10, drive block 44 is maintained on travel axis 46 through use of guide channels 48. When drive block 44 is moved linearly along guide channels 48, the wings 49 on drive block 44 are maintained about guide channels 48. Thus, drive block 44 is ensured of travel along travel axis 46. Trigger 40 contacts drive block 44, and therefore imparts force on drive block 44 along travel axis 46.
Trigger 40 rotates about pivot 41 within handle 50. As seen in FIG. 7, elongated trigger projections 43 contact rear surface 51 of drive block 44. Rotation of the trigger 40 about pivot 41 necessarily causes the user to impart forces on drive block 44 along travel axis 46. This, in turn, causes motion of drive block 44 along travel axis 46, and operation of the stapling mechanism in cartridge 70.
Improvements to the rotating head skin stapler 10 are seen in the driving mechanism employed in use of trigger 40. Drive block 44 has attached to it the pawl 28, by means of tabs 22 folded over the pawl 28, as seen in FIGS. 9 and 10. When trigger 40 is cocked by rotation about pivot 41, drive block 44 causes pawl 28 to move linearly in unison with drive block 44 along axis 46. The rear of drive pawl 28 encounters surface 30a on engagement block 30 at surface 29a on engagement tab 29, as seen especially at FIGS. 5 and 7 in a position normal to travel axis 46. Engagement tab surface 29a becomes enmeshed with engagement block surface 30a to prevent rearward linear motion of drive block 44 along travel axis 46 by holding pawl 28 in teeth 38.
Relying further on FIGS. 6, 7 and 10, upon further motion of the trigger 40, the stopping surface 32 of drive pawl 28 contacts multi-tooth rack 36 on edges 34 of teeth 38. Stopping surface 32 is normal to travel axis 46 and continues to prevent motion of drive block 44 into base 20 in incremental steps throughout the remainder of the stroke of trigger 40. Such continuous maintenance of the position of drive block 44 affirmatively prevents jamming of the stapler 10, by preventing drive block 44 and consequently trigger 40 from retracting linearly along travel axis 46 or recocking during a single stroke of trigger 40. The stapling mechanism in cartridge 70 will not reload, and therefore two staples will not be processed simultaneously at the forming site.
Accordingly, during motion of drive pawl 28 along multi-tooth rack 36, each of the teeth 38 hold drive pawl 28 at stopping surfaces 32 on edges 34 until full rotation of the trigger 40 is accomplished. Then, the pawl 28 acts like a leaf spring and recoils so that the surface of pawl 28 clears the lower surface of multi-tooth rack 36. This occurs because tab 29a is no longer constrained by block surface 30a, so that pawl 28 now moves upward out of engagement with rack 36. This allows drive spring pawl 28 to return to its original position. Return spring 42 causes trigger 40 to return drive block 44 along travel axis 46 after one full stroke of trigger 40.
As further seen in the enlarged view of drive block 44 as in FIG. 10, there are contained on block 44 winged-shaped buffers 26. These wing-shaped buffers 26 provide resistive force encountered by the user during the forward linear motion of drive block 44, near completion of the stroke of the trigger 40. Ordinarily, at the completion of a firing stroke, staples 100 have been formed, but the user continues to drive trigger 40. In order to reduce any "snap" in the feel of the trigger 40, due to the continued force of former 76 against staple crown 106 of the (now formed) staple 100, it is necessary to minimize forward linear motion of drive block 44 and spread the force over a larger surface area by imparting a resistive force opposite the direction of motion of drive block 44, and thus reduce the pressure exerted on drive block 44.
As seen in FIGS. 5, 6 and 8, block-shaped stops 24 are provided in base 20 which engage the buffers 26 near the end of the stroke of trigger 40. These stops 24 contain stopping surfaces 37 which cause the buffers 26 to elastically bend near the end of the stroke of trigger 40. In this way, the force actually imparted by the trigger 40 reduced by spreading forces over a larger surface area near the end of the stroke, and the user experiences no "snap" caused by impact of former 76 on staple 100 after complete staple forming.
In summary, the trigger anti-jamming mechanism and the drive link buffer of the invention accomplish the following steps: The multi-tooth rack 36 provides engagement surfaces 34 on the teeth 38 which are normal to the travel axis 46 and therefore provide a resistive force parallel to the travel axis 46. The drive pawl 28, made of a resilient material to resist permanent deformation, engages the multi-tooth rack 36 in a direction normal to motion of drive block 44 to provide resistive forces parallel to travel axis 46. The engagement tab surface 29a on spring pawl 28 provides early engagement with block engagement surface 30a in order to prevent misfiring of the stapling mechanism in cartridge 70 at an earlier position of trigger 40 stroke. The engagement of the pawl 28 with the rack 36 allows the user to have a smoother feel of the surgical stapling instrument throughout the stroke of trigger 40.
In addition, with the buffers 26 molded as an integral part of the drive block 44, as the stroke of the former 76 approaches the final stage of contact between staple crown 106 and anvil forming surface 94 (as later explained), buffers 26 contact stopping surfaces 32. Because buffers 26 are elastic, they begin to bend and resist any continuing force imparted by drive block 44. In this way, forward motion of the block 44 is slowed and greatly reduces the impact of former 76 against the staple crown 106. This results in a more consistent force to form the staples, and avoids any snap felt by the user during trigger 40 stroke.
Other aspects of the invention are seen in the staple cartridge 70. Specifically, as seen in FIGS. 17 through 19 drive train 66 is connected to former 76 in the cartridge 70 by sliding plate 65 into gripping receiver 75a. Former 76 contacts the first of a group of staples 100 at the head of staple stack 110. These staples 100 contain wings 102, legs 104, and crown 106. Lifter 90 holds a staple 100 in place and maintains staple 100 in position due to forced imparted by spring 88 on lifter 90, as later explained. During formation of a staple 100, crown 106 contacts the forming surface 94 of anvil 78 at a forming site removed from staple stack 110. This is better explained in U.S. Pat. No. 4,811,886, assigned to the common assignee as this invention, and incorporated herein by reference.
As seen in the views of the former 76 in FIGS. 15 and 19, former edges 98 are angled like the gull wing shaped wings 102 and legs 104 of staple 100. The former extends proximally from the rectangular inner profile 99a located between shoulders 99. With the improved former edges 98, the legs 104 become self-centering within staple forming track 120, and force is kept on the inside edges of the staple legs 104 during forming. In so doing, the staple 100 stays centered on former 76 until staple 100 is formed around anvil forming surface 94. Alignment between former 76 and anvil 78 thus becomes the controlling alignment criterion, rather than relying on tolerances of staple 100. If the staple 100 is positioned slightly to one side of the anvil forming surface 94, the funnelling effect of the former edges 98 biases or "pulls" the staple 100 to the center within shoulders 99 and controls it throughout forming of the staple 100. The continuous force imparted on the inside of staple legs 104 during the firing stroke decreases the possibility of malformation of the staple during forming, as seen in FIGS. 15 through 18.
In addition, as seen in FIGS. 15 and 17, anvil forming surface 94 on anvil 78 in the cartridge 70 is smaller in width than staple crown 106. In this way, crown 106 is shaped entirely around anvil forming surface 94. Because the crown 106 is wider than anvil forming surface 94, the cold worked areas of the staple found at the unions of crown 106 and wings 102 are shaped in spaced-apart relationship to the forming surface 94. Thus, the cold worked areas of the staple 100 are avoided during forming about forming surface 94, reducing forces necessary to form a staple 100.
Another improvement is seen in the lifter mechanism in cartridge 70 of the stapler. Lifter 90 is controlled by lifter spring 88 on the lower staple housing 82 of staple cartridge 70. Lifter spring 88 causes lifter 90 to move one staple 100 from the stack of staples 110 in staple feeding track 82a of the lower staple housing 82 of the cartridge 70. The staples in stack 110 are moved along feeding track 82a by feeder shoe 84, which is urged distally by feeder spring 86. Lifter spring 88 causes lifter 90 to lift a staple 100 across profile 96 in intermediate staple housing 74, which defines a vertical passage between parallel feeding track 82a and forming track 120.
The profile 96 on intermediate staple housing 74 has a shape corresponding to the staples 100 maintains the staple 100 on lifter 90 properly within tab 74a of intermediate housing 74. Lifter 90 therefore prevents transfer and double loading of staples from the stack of staples in feeding track 82a onto the staple forming stack 120.
Retainer cap 72 holds together upper staple housing 80 and lower staple housing 82 and maintains feeder spring 86 in cartridge 70 so that the force urging staple stack 110 along feeder track 82a and into a staple forming track 120 is uninterrupted. Staple kick-off spring 92 causes the formed staples 100 to be kicked off from the anvil forming surface 94 when formed and placed in the skin and former 76 is retracted. Top staple housing 80 of cartridge 70 comprises the upper surface of forming track 120.
The staple transfer mechanism found in lifter 90 lifts the staple between the parallel staple stack 110 in staple feeding track 82a and staple forming track 120 incorporated in cartridge 70. The single staple 100 is supported along its crown 106 and legs 104 by the lifter 90 during lifting from the staple feeding track 82a to staple forming position in staple forming track 120. Tab 75 located on the distal end of the intermediate staple guide 74 provides resistive force to the motion of staple lifter 90 and maintains the staple in contact with lifter 90 and profile 96 through motion between the staple feeding track 82a and staple forming track 120. Ears 90a on lifter 90 protrude transversely into channels 82b of lower staple housing 82 to guide motion of lifter 90. This staple transfer mechanism allows for reliable staple feeding in the staple cartridge 70 within a thin profile. This allows for improved visible staple placement onto the surgical site.
While the invention has been described in connection with a particularly preferred embodiment, it will be understood that the following claims and their equivalents are meant to describe the invention. | A surgical stapler having a trigger attached to a ratcheting mechanism for preventing the refiring of the stapler trigger with a staple loaded within a forming mechanism. In addition, the mechanism contains driver buffering means to prevent the sharp reduction in opposing force driving formation of a staple. The staples are constantly maintained in proper orientation during transfer from a track to the forming site, and are self-centering on the former, and have an oversized crown so that cold-worked areas on each staple do not hinder forming. | 0 |
FIELD OF THE INVENTION
[0001] The invention relates to virtualization software for computer systems. In particular the invention relates to protecting the contents of a virtual disc by encrypting and decrypting the virtual disc.
BACKGROUND
[0002] Setting up or installing large numbers of servers and computer systems with specific software and applications using conventional physical resources has become more and more costly. In recent years this process has become simplified by the use of virtualization technologies providing virtual discs or operating systems with preconfigured software packages and system configurations.
[0003] If a large number of like configured servers is needed, the same virtual disc can be used over and over again. Virtual disc images may be distributed via the internet. However the packets containing the virtual disc image may contain critical data and licenses. In addition, the unauthorized use of virtual disc images needs to be prevented. Currently the entire disc image is encrypted before being distributed.
SUMMARY OF THE INVENTION
[0004] The invention provides a computer-readable storage medium containing instructions for encrypting a virtual disc, a computer-readable storage medium containing instructions for decrypting an encrypted virtual disc, and an encrypted-virtual-disc computer-readable storage medium containing the virtual disc in the independent claims. Embodiments are given in the dependent claims.
[0005] Encrypting all of the virtual disc images before distribution has several disadvantages. First a virtual disc image in one format may not be converted into another without being decrypted. Secondly, an administrator is needed to decrypt and install the virtual disc image. This could be a problem, because a cryptographic key or credentials for decrypting the virtual disc image need to be provided to the administrator. The end user or operator of the virtual disc system may or may not wish to share the cryptographic key or credentials with the administrator.
[0006] Embodiments of the invention may solve these and other problems by placing an encryption-master-boot-record on the encrypted virtual disc image along with a decryption program for decrypting an at least partially encrypted virtual disc image. The encryption-master-boot-record is a master boot record which is used for booting the virtual machine. The virtual machine then decrypts the encrypted virtual disc image using the decryption program and cryptographic credentials. This eliminates the need to provide the operator with the cryptographic credentials.
[0007] Embodiments of the invention may have the advantage that the virtual disc may be encrypted or decrypted from the virtual disc. Embodiments of the invention may have the advantage that the method can be set up to encrypt only used blocks. This results in faster encryption and a reduction in the amount of data to encrypt. Embodiments of the invention may have the advantage that a virtual disc can be encrypted and decrypted on the fly.
[0008] Additionally, only portions of the virtual disc may be encrypted. For instance, the blocks of the virtual disc may be selectively encrypted. The portions of the virtual disc which contain data or records specific to a particular format of virtual disc can be left unencrypted. This allows the conversion of the virtual disc without decrypting the virtual disc.
[0009] A computer-readable storage medium as used herein encompasses any tangible storage medium which may store instructions which are executable by a processor of a computing device. The computer-readable storage medium may be referred to as a computer-readable non-transitory storage medium. The computer-readable storage medium may also be referred to as a tangible computer-readable medium. In some embodiments, a computer-readable storage medium may also be able to store data which is able to be accessed by the processor of the computing device.
[0010] Examples of computer-readable storage media include, but are not limited to: a floppy disc, a magnetic hard disc drive, a solid state hard disc, flash memory, a USB thumb drive, Random Access Memory (RAM) memory, Read Only Memory (ROM) memory, an optical disc, a magneto-optical disc, and the register file of the processor. Examples of optical discs include Compact Discs (CD) and Digital Versatile Discs (DVD), for example CD-ROM, CD-RW, CD-R, DVD-ROM, DVD-RW, or DVD-R discs. The term computer-readable storage medium also refers to various types of recording media capable of being accessed by the computer device via a network or communication link. For example a data may be retrieved over a modem, over the internet, or over a local area network.
[0011] Computer memory is an example of a computer-readable storage medium. Computer memory is any memory which is directly accessible to a processor. Examples of computer memory include, but are not limited to: RAM memory, registers, and register files.
[0012] Computer storage is an example of a computer-readable storage medium. Computer storage is any non-volatile computer-readable storage medium. Examples of computer storage include, but are not limited to: a hard disc drive, a USB thumb drive, a floppy drive, a smart card, a DVD, a CD-ROM, and a solid state hard drive. In some embodiments computer storage may also be computer memory or vice versa.
[0013] A computing device or computer system as used herein refers to any device comprising a processor. A processor as used herein encompasses an electronic component which is able to execute a program or machine executable instruction. References to the computing device comprising “a processor” should be interpreted as possibly containing more than one processor. The term computing device should also be interpreted to possibly refer to a collection or network of computing devices each comprising a processor. Many programs have their instructions performed by multiple processors that may be within the same computing device or which may even be distributed across multiple computing devices.
[0014] A user interface as used herein is an interface which allows a user or operator to interact with a computer or computer system. A user interface may provide information or data to the operator and/or receive information or data from the operator. The display of data or information on a display or a graphical user interface is an example of providing information to an operator. The receiving of data through a keyboard, mouse, trackball, touchpad, pointing stick, graphics tablet, joystick, gamepad, webcam, headset, gear sticks, steering wheel, pedals, wired glove, dance pad, remote control, and accelerometer are all examples of receiving information or data from an operator.
[0015] Virtualization software, a virtualization program, and a virtualization module as used herein all refer to software or computer executable instructions which allow a computer system to run a virtual computer system. A virtual machine or virtual computer system as used herein encompasses a computer system which is implemented virtually or simulated by software running on a computer system.
[0016] A cryptographic key or cryptographic credential as used herein encompasses a key, credential, or password which may be used by a decryption algorithm to decrypt a data file.
[0017] A virtual disc as used herein encompasses data which may be used by a virtualization program as a virtual disc image. A virtual disc may contain a file system which may be accessed by the virtualization system or virtual system. A virtual disc may also contain a bootable operating system.
[0018] In one aspect the invention provides for a computer-readable storage medium containing machine executable instructions that when executed by a processor cause a processor to encrypt a virtual disc. The virtual disc comprises a virtual disc image. The virtual disc image is an image of an existing disc file system or a disc file system which is constructed for the purpose of creating the virtual disc image. Execution of the machine executable instructions causes the processor to receive the virtual disc. Execution of the machine executable instructions further causes the processor to increase the size of the virtual disc. The virtual disc may essentially be a file stored on the computer-readable storage medium or a different computer-readable storage medium. The size of the virtual disc may be increased by adding blocks at the beginning or the end of the virtual disc. Execution of the machine executable instructions further cause the processor to write a decryption-master-boot-record and a decryption program to the virtual disc. The decryption-master-boot-record is a master boot record that a virtual computer or computer system boots into when using the virtual disc image. The decryption-master-boot-record allows the virtual computer system to run the decryption program for decrypting the virtual disc. Execution of the machine executable instructions further causes the processor to encrypt at least a portion of the virtual disc image. The decryption program comprises decryption-machine-executable-instructions for decrypting the at least partially encrypted virtual disc image in accordance with a cryptographic key. The virtual disc image is encrypted such that the virtual disc image may be decrypted using the decryption program in accordance with the cryptographic key.
[0019] In some embodiments the entire virtual disc image is encrypted. In other embodiments only certain portions of the virtual disc image are encrypted. For instance, if portions of the virtual disc are unused, these portions of the disc image need not be encrypted. It may also be able to be determined if certain portions of the virtual disc contain sensitive information that will be desirable to protect by encryption, for instance application programs or sensitive data. The decryption of the virtual disc image could be speeded up by selectively using those portions of the virtual disc which need to be protected and not encrypting those portions which do not need to be protected.
[0020] Embodiments of the invention have several advantages. For instance, adding the decryption-master-boot-record to the virtual disc and the decryption program enables an end user to perform the decryption of the virtual disc image. This eliminates the need for an administrator to perform this task.
[0021] In another embodiment the virtual disc image is divided into first and second parts. The virtual disc is divided into first, second, third, fourth, and fifth portions. The virtual disc image originally spans the first, second, and third portions of the virtual disc. The second part of the virtual disc image is stored in a third portion of the virtual disc. Execution of the instructions further cause the processor to copy the first part of the virtual disc image to a fourth portion of the virtual disc. The first part of the virtual disc image is copied or moved from the first and second portions of the virtual disc to the fourth portion of the virtual disc. The decryption-master-boot-record is written to the first portion of the virtual disc. When the virtual disc is loaded into a virtual system and the virtual system boots into the virtual disc the decryption-master-boot-record will cause the virtual system to run the decryption program.
[0022] The decryption program is written to the second portion of the virtual disc. As mentioned above, the first part of the virtual disc image is copied from the first and second portions of the virtual disc. The first part of the virtual disc image is copied from the first and second portions of the virtual disc before the decryption-master-boot-record and the decryption program are written to the first and second portions of the virtual disc respectively. Execution of the instructions further causes the processor to at least partially encrypt the first and second parts of the virtual disc. The size of the virtual disc is increased to create the fourth portion of the virtual disc and a fifth portion of the virtual disc. The size of the fifth portion is larger than or equal to the second portion. The combined size of the first and second portions is less than or equal to the size of the fourth portion. This embodiment of the invention may be advantageous because the decryption-master-boot-record is in the first portion and will cause the virtual system to boot into the decryption program.
[0023] In another embodiment the first part of the virtual disc image is encrypted together. In this embodiment the entire first part of the virtual disc image is encrypted as a single encrypted data file.
[0024] In another embodiment the second part of the virtual disc image is encrypted together. In this embodiment the second part of the virtual disc image is encrypted as a single data file.
[0025] In another embodiment the virtual disc image is divided into blocks. As used herein a block is a portion or sub-division of data of a disc or a virtual disc image. The data in a block is addressable by the disc or the virtual disc. The blocks are selectively encrypted in accordance with a predetermined block encryption list. The block encryption list is a list of blocks which are to be encrypted during the encryption of the virtual disc image. For instance an operator could determine which blocks of the virtual disc image contain data which is desired to be protected by encryption. For instance these blocks may contain sensitive data or information. Likewise these blocks may contain applications for which a license is to be purchased. If the program is transmitted across the internet it would be desirable to protect the executable version of the code or data.
[0026] In another embodiment the virtual disc image is divided into blocks. Execution of the instructions causes the processor to examine each of the blocks and create a list of unused blocks. Particular blocks are encrypted only if they are not found in the list unused blocks. This embodiment is particularly advantageous because the computer-readable storage medium avoids encrypting blocks which are not used. Since the blocks are not used there is no need to protect them. In some virtual file systems unused data may be part of the file system but not used. By not encrypting these portions of the file system the virtual disc may be smaller.
[0027] The aforementioned embodiments of the computer-readable storage medium also provide for other aspects of the invention. For instance a computer system is provided for by the invention which contains or comprises the machine readable instructions contained on a computer-readable storage medium according to an embodiment of the invention. Likewise execution of the machine executable instructions causes the processor to perform various steps or actions which also provide for a method and computer-implemented methods. The executable instructions on the computer-readable storage medium also provide for a computer program product and/or a computer system.
[0028] Another aspect of the invention provides for a computer-readable storage medium containing machine executable instructions that when executed by a processor cause the processor to decrypt an encrypted virtual disc. The virtual disc comprises a decryption-master-boot-record, a decryption program, and an at least partially encrypted virtual disc image. The decryption program comprises decryption-machine-executable-instructions for decrypting the at least partially encrypted virtual disc image in accordance with a cryptographic key. Execution of the machine executable instructions causes the processor to receive the encrypted virtual disc.
[0029] Execution of the machine executable instructions further causes the processor to boot a virtual machine using the decryption-master-boot-record. Execution of the machine executable instructions further causes the processor to receive the cryptographic key. The order of receiving the cryptographic key is not critical. For instance the processor could receive the cryptographic key at any point before the virtual disc image is decrypted. Execution of the machine executable instructions further cause the processor to decrypt the at least partially encrypted virtual disc image in accordance with the cryptographic key and the decryption program. The machine executable instructions cause the processor to boot the virtual machine and the virtual machine boots into the operating system on the encrypted virtual disc via the decryption-master-boot-record. This then causes the virtual machine to run the decryption program. The decryption program then decrypts the at least partially encrypted virtual disc image. Both the cryptographic key and the decryption program are needed for decrypting the at least partially encrypted virtual disc image.
[0030] In another embodiment the decryption of the at least partially encrypted virtual disc image is performed during deployment of the virtual machine. In the current state of the art an administrator will receive an encrypted virtual disc and the administrator is responsible for decrypting it. This is however undesirable in many circumstances because the end user or operator of the virtual machine relies on an administrator to perform the decryption. Embodiments of the invention may have the advantage that the end user or operator can perform the decryption his or herself.
[0031] In another embodiment the virtual disc comprises a first portion containing the decryption-master-boot-record. The virtual disc further comprises a second portion containing the decryption program. The virtual disc further comprises a third portion containing a second part of the virtual disc image. The virtual disc further comprises a fourth portion containing a first part of the virtual disc. The first part of the virtual disc may contain in some embodiments a master boot record for booting into an operating system contained in the virtual disc image. This master boot record in the fourth portion may be used to boot the virtual machine once the decryption of the at least partially encrypted virtual disc is completed.
[0032] The virtual disc comprises a fifth portion containing storage space. The size of the fifth portion is larger than the second portion. The combined size of the first and second portions is less than or equal to the size of the fourth portion. The combined size of the first and second portions is less than or equal to the size of the fourth portion. The at least partially encrypted disc image is decrypted by decrypting the second part of the virtual disc image. The at least partially encrypted virtual disc image is further decrypted by copying the decryption program to the fifth portion of the virtual disc. The at least partially encrypted virtual disc image is decrypted by decrypting a portion of the first part of the virtual disc image.
[0033] The at least partially encrypted virtual disc image is further decrypted by copying the decrypted portion of the first part of the virtual disc image to the second portion of the virtual disc. The virtual disc image is further decrypted by decrypting the remainder of the first part of the virtual disc image. The virtual disc image is further decrypted by copying the decrypted remainder of the first part of the virtual disc image to the first portion of the virtual disc. Performing the decryption in this manner may have the advantage that the decryption can be interrupted at any point in time. For instance the fifth portion may contain a data file which maintains a status of the decryption process.
[0034] In another embodiment execution of the instructions further causes the processor to erase data in the fourth and fifth portions of the virtual disc after copying the decrypted remainder of the first part of the virtual disc image to the first portion of the virtual disc.
[0035] In another embodiment execution of the instructions further causes the virtual machine to reboot after decrypting the at least partially encrypted virtual disc image.
[0036] The aforementioned embodiments of the computer-readable storage medium also provide for other aspects of the invention. For instance a computer system is provided for by the invention which contains or comprises the machine readable instructions contained on a computer-readable storage medium according to an embodiment of the invention. Likewise execution of the machine executable instructions causes the processor to perform various steps or actions which also provide for a method and computer-implemented methods. The executable instructions on the computer-readable storage medium also provide for a computer program product and/or a computer system.
[0037] In another aspect the invention provides for an encrypted-virtual-disc computer-readable storage medium containing a virtual disc. The virtual disc comprises a decryption-master-boot-record, a decryption program, and an at least partially encrypted virtual disc image. The decryption program comprises machine executable instructions for decrypting the at least partially encrypted virtual disc in accordance with a cryptographic key. In other words the combination of the decryption program and the cryptographic key are used for decrypting the at least partially encrypted virtual disc image.
[0038] The decryption program comprises machine executable instructions that when executed by a processor cause the processor to receive a cryptographic key. The cryptographic key may in some embodiments be prompted to be entered by the decryption program or the cryptographic key may be passed to the decryption program by another program. For instance virtualization software for running a virtual computer system may pass a cryptographic key on to the decryption program. Further execution of the machine executable instructions of the decryption program cause the processor to decrypt the at least partially encrypted virtual disc image in accordance with the cryptographic key and the decryption program.
[0039] In another embodiment the virtual disc comprises a first portion containing the decryption-master-boot-record. The virtual disc further comprises a second portion containing the decryption program. The virtual disc further comprises a third portion containing a second part of the virtual disc image. The virtual disc further comprises a fourth portion containing a first part of the virtual disc. The virtual disc further comprises a fifth portion containing storage space. The size of the fifth portion is larger than or equal to the second portion. The combined size of the first and second portions is less than or equal to the size of the fourth portion.
[0040] In another embodiment the at least partially encrypted virtual disc image is decrypted by decrypting the second part of the virtual disc image. The virtual disc is further decrypted by copying the decryption program to the fifth portion of the virtual disc. The virtual disc image is further decrypted by decrypting a portion of the first part of the virtual disc image. The virtual disc is further decrypted by copying the decrypted portion of the first part of the virtual disc image to the second portion of the virtual disc. The virtual disc is further decrypted by copying the decrypted portion of a first part of the virtual disc image to the second portion of the virtual disc. The virtual disc image is further decrypted by decrypting the remaining of the first part of the virtual disc image. The virtual disc image is further decrypted by copying the decrypted remainder of the first part of the virtual disc image to the first portion of the virtual disc.
[0041] In another embodiment the virtual disc contains a decryption-status-data-file for storing the progress of the decryption of the at least partially encrypted virtual disc image. Execution of the machine executable instructions of the decryption program further cause the processor to update the decryption-status-data-file during decryption of the at least partially encrypted virtual disc image. Execution of the machine executable instructions of the decryption program further cause the processor to check the decryption-status-data-file when starting the decryption of the at least partially encrypted virtual disc image. By checking the status of the decryption-status-data-file the decryption can be started at an intermediate point if the decryption was originally interrupted.
[0042] In another embodiment execution of the instructions further cause the processor to erase data in the fourth and fifth portion of the virtual disc after copying the decrypted remainder of the first part of the virtual disc image to the first portion of the virtual disc.
[0043] In another embodiment execution of the instructions further cause a virtual machine executing the decryption program to reboot after decrypting the at least partially encrypted virtual disc image.
[0044] The aforementioned embodiments of the computer-readable storage medium also provide for other aspects of the invention. For instance a computer system is provided for by the invention which contains or comprises the machine readable instructions contained on a computer-readable storage medium according to an embodiment of the invention. Likewise execution of the machine executable instructions causes the processor to perform various steps or actions which also provide for a method and computer-implemented methods. The executable instructions on the computer-readable storage medium also provide for a computer program product and/or a computer system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] In the following, preferred embodiments of the invention will be described in greater detail by way of example only making reference to the drawings in which:
[0046] FIG. 1 illustrates the decryption of a virtual disc 100 according to an embodiment of the invention,
[0047] FIG. 2 illustrates an example of decryption during importation of the virtual system,
[0048] FIG. 3 illustrates the decryption of the virtual disc image during deployment,
[0049] FIGS. 4 a - 4 e illustrate a method of block-based encryption of a virtual disc image according to an embodiment of the invention,
[0050] FIGS. 5 a - 5 d illustrate the decryption of the virtual disc image encrypted in FIGS. 4 a - 4 e,
[0051] FIG. 6 shows a flow diagram which illustrates a method of encrypting a virtual disc image according to a further embodiment of the invention,
[0052] FIG. 7 shows a flow diagram which illustrates a method of decrypting a virtual disc image according to a further embodiment of the invention,
[0053] FIG. 8 shows a flow diagram which illustrates a method of decrypting a virtual disc image according to a further embodiment of the invention, and
[0054] FIG. 9 illustrates a first computer system for encrypting a virtual disc and a second computer system for decrypting a virtual disc.
DETAILED DESCRIPTION
[0055] In the following, like numbered elements in these figures are either similar elements or perform an equivalent function. Elements which have been discussed previously will not necessarily be discussed in later figures if the function is equivalent.
[0056] FIG. 1 illustrates the decryption of a virtual disc 100 according to an embodiment of the invention. The virtual disc 100 comprises a virtual disc image 102 which is encrypted and a decryption program 104 for decrypting the virtual disc image 102 . FIG. 1 also shows a computer system 106 which contains virtualization software for running virtual computer systems or machines. Shown in FIG. 1 is an operator 108 and a user 110 . FIG. 1 illustrates the actions taken by the operator 108 and the user 110 when using a virtual disc 100 according to an embodiment of the invention. The steps shown in FIG. 1 are for the first booting of the virtual disc and its decryption. Step 1 is labeled 112 . In this step the operator 108 stores the virtual disc 100 on the computer system 106 . In step 2 ( 114 ), the user 110 boots the virtual machine using the virtualization software on a computer system 106 . In step 3 ( 116 ), the decryption program 104 starts and requests credentials or a password from the user 110 . In step 4 ( 118 ), the user 110 provides the credentials or password to the decryption program 104 . In step 5 ( 120 ), the decryption program 104 decrypts the virtual disc image 102 using the credentials or password. In step 6 ( 122 ), the virtual machine reboots and the virtual machine boots from the decrypted virtual disc image 102 .
[0057] During use of a virtual disc 100 , according to an embodiment of the invention, two different use scenarios are possible. There may be decryption during the import of the virtual disc image 102 or there may be decryption during deployment of the virtual disc image 102 . If the virtual disc image 102 is decrypted during the importation of the virtual system the operator knows the credentials and passes this to the program or programs for managing the virtual systems. The programs for managing the virtual system then import the image and decrypt it on the fly. For the second possibility for decryption during deployment, the operator does not know the credentials and asks to import the images without decrypting. The virtual disc image is stored in a database of virtual systems. At deployment time the user is prompted for the credentials.
[0058] FIG. 2 shows an example of decryption during importation of the virtual system. Shown in FIG. 2 is a computer system 200 that functions as a virtual system image server 202 . The virtual system image server 202 serves images of virtual systems when requested by an operator 208 . Also stored or able to be accessed by the computer system 200 is a virtual disc repository 204 , which is a repository of virtual discs accessible via the virtual system image server 202 . There is also a decryption module 206 that is equivalent to the decryption program 104 shown in FIG. 1 . In step 1 the operator 208 downloads a virtual disc. In step 2 ( 212 ), the operator requests the importation of the virtual disc into the system managed by the virtual system image server 202 . In step 3 ( 214 ), the virtual system image server 202 requests credentials or a password from the operator 208 . In step 4 ( 216 ), the operator 208 provides the credentials or passwords to the virtual system image server 202 . In step 5 ( 218 ), the virtual system image server 202 imports the virtual disc image from the virtual disc and decrypts the virtual disc image on the fly using the credentials or passwords provided by the operator 208 .
[0059] FIG. 3 illustrates the decryption of the virtual disc image during deployment. Shown in this figure is a computer system 200 with a virtual system image server 202 that manages virtual disc images stored in a virtual disc repository 204 . In the example shown in FIG. 3 there is a second computer system 300 that is used for decryption during the deployment of the virtual disc image. The second computer system 300 is for running a target virtual system 302 . Within the target system 302 is an operating system deployment tool 301 . The operating system deployment tool 301 is provided to deploy a virtual system in a virtual disc image.
[0060] Also within the target virtual system is a decryption module 303 . The decryption module is a software module or decryption program for decrypting a virtual disc image using a password or a cryptographic credential. An operator 304 and a user 306 are shown. In a first step 1 designated by reference 308 , the operator 304 requests or triggers the deployment of a virtual system on the second computer system 300 . In a second step 2 (designated by reference 310 ) the target or virtual system boots on the operating system deployment tool 301 . In a third step 3 (designated by reference 312 ), the operating system deployment tool 301 requests a cryptographic password or credentials from the user 306 . In a fourth step 4 (designated by reference 314 ), the user 306 provides the cryptographic password or credentials to the operating system deployment tool 301 . In a fifth step 5 (also referred to as 316 ), the operating tool downloads and decrypts the virtual disc image using the cryptographic password or credentials and the decryption module 303 . In step 6 (also referred to as 318 ), after the virtual disc image has been decrypted, the deployment of the virtual system continues on the decrypted virtual disc image.
[0061] FIGS. 4 a to 4 e illustrate a method of block-based encryption of a virtual disc image according to an embodiment of the invention. In FIG. 4 a , a virtual disc 400 and a virtual disc image 402 are shown. The blocks which make up the virtual disc image are labeled 1 -n. To encrypt the virtual disc image the user starts an encryption tool or program. In a first step the decryption tool increases the size of the virtual disc. This is illustrated in FIG. 4 b . At the end of the virtual disc 400 a region of empty operating system blocks 404 is created. In a next step the virtual disc image is divided into a first part 406 and a second part 408 . The first part of the virtual disc image 406 is copied to the empty operating system blocks 404 at the end of the virtual disc 400 .
[0062] In FIG. 4 d , it is shown that the encryption tool copies a decryption master boot record 410 and a decryption program 412 to a first and second part of the virtual disc 400 . FIG. 4 e illustrates the final step. The encryption tool or software encrypts the first part of the virtual disc image 406 ′ and encrypts the second part of the virtual disc image 408 ′. All of the blocks of the encrypted virtual disc image 406 ′, 408 ′ may be encrypted or the blocks may be selectively encrypted. In FIG. 4 e the virtual disc 400 is also shown as being divided into five portions. The first portion of the virtual disc 414 contains the decryption-master-boot-record 410 . The second portion of the virtual disc 416 contains the decryption program 412 . The third portion of the virtual disc 418 contains the encrypted 408 ′ second part of the virtual disc image. The fourth portion of the virtual disc 420 contains the encrypted 406 ′ first part of the virtual disc image. The fifth portion of the virtual disc 422 is at the end of the virtual disc 400 . In various embodiments the fifth portion 422 may contain data recording the decryption state, journaling data, temporary data used in the decryption, and combinations thereof.
[0063] FIGS. 5 a - 5 d illustrate the decryption of the virtual disc image 406 ′, 408 ′ of a virtual disc 400 when booted from a virtual machine. FIG. 5 a is identical with FIG. 4 e . In a first step the virtual machine boots on the virtual disc 400 and boots into the virtual disc master boot record 410 . Next the master boot record 410 loads the decryption program 412 . The decryption program 412 then requests cryptographic credentials or a password for use for decrypting the encrypted virtual disc image 406 ′, 408 ′. In FIG. 5 b the decryption process is illustrated. Two different views of the virtual disc 400 are shown. Blocks labeled 500 are decrypted blocks of the second part of the virtual disc image. Blocks labeled 502 are encrypted blocks of the second part of the virtual disc image. In the top view shown in FIG. 5 b only the block labeled 4 is a decrypted block 500 . The remainder of the second part of the virtual disc image is encrypted. The bottom part of FIG. 5 b shows that all blocks of the second part of the virtual disc image 408 are decrypted blocks 500 .
[0064] FIG. 5 c shows further progress in decrypting the virtual disc 400 . After all blocks of the second part of the virtual disc image 408 have been decrypted the decryption program 412 is copied to the fifth portion 422 of the virtual disc. Next a portion of the first part of the virtual disc image 406 ′ is decrypted and copied to the second portion 416 of the virtual disc. The remainder 506 of the first part of the virtual disc image 406 ′ is decrypted and copied to the first portion 414 of the virtual disc. The remainder of the first part of the virtual disc image 506 in this embodiment has overwritten the master boot record 410 . The encrypted first part of the virtual disc image 406 ′ and the decryption program 412 may be overwritten leaving empty operating system blocks 404 . The Fig. shown in 5 d is equivalent with that shown in FIG. 4 b . This shows how the method illustrated in FIG. 5 has been used to decrypt the at least partially encrypted virtual disc image 402 of the virtual disc 400 .
[0065] FIG. 6 shows a flow diagram which illustrates an embodiment of encrypting a virtual disc image according to the invention. In step 600 a virtual disc is received. The virtual disc comprises a virtual disc image. In step 602 the size of the virtual disc is increased. In step 604 a decryption-master-boot-record and a decryption program are written to the virtual disc. In step 606 at least a portion of the virtual disc image is encrypted.
[0066] FIG. 7 shows a flow diagram which illustrates a method of decrypting a virtual disc according to an embodiment of the invention. In step 700 an encrypted virtual disc is received. In step 702 a virtual machine is booted using a decryption-master-boot-record contained on the virtual disc. In step 704 a cryptographic key is received. The virtual disc comprises an at least partially encrypted virtual disc. In step 706 the at least partially encrypted virtual disc is decrypted using a decryption program which is on the virtual disc. The decryption program uses the cryptographic key for decrypting with the decryption program for performing the decryption of the at least partially encrypted virtual disc.
[0067] FIG. 8 shows a flow diagram which illustrates a method of decrypting an encrypted virtual disc according to a further embodiment of the invention. In step 800 an encrypted virtual disc is received. In step 802 a virtual machine is booted using the decryption-master-boot-record. In step 804 a cryptographic key is received. In step 806 a second part of the virtual disc image is decrypted using the cryptographic key and a decryption program which is located on the virtual disc. In step 808 the decryption program is copied to a fifth portion of the virtual disc. In step 810 a portion of a first part of the virtual disc image is decrypted. In step 812 the decrypted portion of the first part of the virtual disc image is copied to the second portion of the virtual disc. In step 814 the remainder of the first part of the virtual disc image is decrypted. In step 816 the decrypted remainder of the first part of the virtual disc image is copied to the first portion of the virtual disc. In step 818 the virtual machine is rebooted. The method illustrated in FIG. 8 is analogous to the method illustrated by FIG. 5 .
[0068] FIG. 9 shows two computer systems, a first computer system 900 for encrypting a virtual disc and a second computer system 902 for decrypting a virtual disc. There is a network communication 904 between the first computer system 900 and the second computer system 902 . The first computer system has a network interface 906 for connecting to the computer network 904 and the second computer system 902 has a network interface 908 for connecting to the computer interface 904 . The network connection 904 can be any standard computer interface such as an Ethernet connection or an internet connection. The first computer system 900 has a processor 910 that is connected to a user interface 912 and the network interface 906 . The processor 910 is also connected to computer storage 914 and computer memory 916 .
[0069] Within the computer storage 914 is an unencrypted virtual disc 918 . The unencrypted virtual disc contains an unencrypted virtual disc image. Also within the computer storage 914 is a decryption-master-boot-record 920 . Also within the computer storage 914 is a decryption program 922 . Also within the computer storage 914 is an encrypted virtual disc 924 . The encrypted virtual disc 924 contains a decryption-master-boot-record 920 , a decryption program 922 , and an at least partially encrypted virtual disc image 923 . The encrypted virtual disc 924 may also contain an at least partially encrypted virtual disc image. The computer memory 916 contains an encryption tool 926 . An encryption tool 926 is a software module or program containing machine executable instructions that cause the processor 910 to create the encrypted virtual disc 924 using the unencrypted virtual disc 918 , the decryption-master-boot-record 920 , and the decryption program 922 . The encryption tool 926 may be used to implement the methods illustrated in FIGS. 4 and 6 . In some embodiments the computer memory 916 also contains a cryptographic module and a cryptographic credential generation module 930 . The cryptographic module 928 is used for encrypting the unencrypted virtual disc 918 . The cryptographic credential generation module 930 is an optional module and may be used for generating cryptographic credentials. For instance the cryptographic credential generation module may be used to generate a cryptographic key pair for an asymmetric encryption algorithm.
[0070] The second computer system 902 also contains a processor 932 . The processor 932 is connected to the network interface 908 and the user interface 934 . The processor 932 is also connected to computer storage 936 and computer memory 938 . The computer storage 936 contains the encrypted virtual disc 924 from the first computer system 900 . In this embodiment the network connection 904 was used to transfer the encrypted virtual disc 924 . Also within the computer storage 936 is an encryption cryptographic key 944 . Computer memory 938 contains a virtualization module 942 . The virtualization module 942 allows the processor 932 to run and operate a virtual computer system. As can be seen, all that is needed to decrypt the encrypted virtual disc 924 is the virtualization module 942 and the cryptographic key 944 . This Fig. also illustrates how an end user may be able to decrypt the encrypted virtual disc 924 without the aid of an operator. | Encryption of virtual disc image is accomplished by increasing the size of a virtual disc to support the inclusion of a master boot record and a decryption program. Encrypting portions of a virtual disc image on the virtual disc, but leaving the boot record and decryption program unencrypted and accessible, where the decryption program will decrypt the encrypted portions if the appropriate cryptographic key is supplied. Subsequent decryption is accomplished by initiating a boot sequence through the master boot record, receiving the appropriate cryptographic key, appropriately ordering the decrypted disc image. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/335,701, filed Oct. 26, 2001, the entire disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to oil production, and more particularly to an improved method for recovering oil from subterranean oil reservoirs with the aid of electric current.
BACKGROUND OF THE INVENTION
[0003] When crude oil is initially recovered from an oil-bearing earth formation, the oil is forced from the formation into a producing well under the influence of gas pressure and other pressures present in the formation. The stored energy in the reservoir dissipates as oil production progresses and eventually becomes insufficient to force the oil to the producing well. It is well known in the petroleum industry that a relatively small fraction of the oil in subterranean oil reservoirs is recovered during this primary stage of production. Some reservoirs, such as those containing highly viscous crude, retain 90 percent or more of the oil originally in place after primary production is completed. Oil recovery is frequently limited by capillary forces that impede the flow of viscous oil through interstitial spaces in the oil-bearing formation.
[0004] Numerous methods have been proposed for recovering additional oil that remains the in oil-bearing formations following primary production. These secondary recovery techniques generally involve the expenditure of energy to supplement the expulsive forces and/or to reduce the retentive forces acting on the residual oil. A summary of secondary recovery techniques may be found in U.S. Pat. No. 3,782,465, the entire disclosure of which is incorporated by reference herein.
[0005] One secondary recovery technique for promoting oil recovery involves the application of electric current through an oil body to increase oil mobility and facilitate transport to a recovery well. Typically, one or more pairs of electrodes are inserted within the underground formation at spaced-apart locations. A voltage drop is established between the electrodes to create an electric field through the oil formation. In some processes, electric current is applied to raise the temperature of the oil formation and thereby lower the viscosity of the oil to facilitate removal. Other methods use electric current to move the oil towards a recovery well by electroosmosis. In electroosmosis, dissolved electrolytes and suspended charged particles in the oil migrate toward a cathode, carrying oil molecules with them. These methods typically use a DC potential source to generate an electrical field across the oil-bearing formation.
[0006] Oil recovery methods that utilize electrodes frequently encounter problems affecting the quantity and quality of the recovered oil. Systems using straight DC voltage typically operate under high voltages and currents. In addition, systems using DC current consume relatively large amounts of electricity with corresponding large energy costs.
SUMMARY OF THE INVENTION
[0007] With the foregoing in mind, the present invention provides an improved method for stimulating oil recovery from an oil-bearing underground formation through the use of electric current. Electric current is introduced through a plurality of boreholes installed in the formation. In systems using only two boreholes, a first borehole and a second borehole are provided in the proximity of the underground formation. The boreholes are located at spaced-apart locations in or near the formation. A first electrode is placed into the first borehole and a second electrode is placed into the second borehole. A source of voltage is then connected to the first and second electrodes. The second borehole may penetrate the body of oil in the underground formation or be located beyond the oil body, so long as some or all of the oil body is located between the second borehole and the first electrode. The first and second boreholes may penetrate the body of oil to be recovered, or they may penetrate the formation at a point beyond but in proximity to the body of oil.
[0008] The first and second electrodes are installed in an electrically conductive formation, such as a formation having a moisture content sufficient to conduct electricity. A DC biased current with a ripple component is applied through the electrodes under conditions appropriate to create an electrical field through the oil formation. The current is regulated to stimulate oxidation and reduction reactions in the oil. As redox reactions occur, long-chain compounds such as heavy petroleum hydrocarbons are reduced to smaller-chain compounds. The decomposition of long-chain compounds decreases the viscosity of the oil compounds and increases oil mobility through the formation such that the oil may be withdrawn at the recovery well. Electrochemical reactions in the formation also upgrade the quality and value of the oil that is ultimately recovered. The system can be used with a multiplicity of cathodes and anodes placed in vertical, horizontal or angular orientations and configurations.
DESCRIPTION OF THE DRAWINGS
[0009] The foregoing summary as well as the following description will be better understood when read in conjunction with the accompanying figures, in which:
[0010] [0010]FIG. 1 is a schematic diagram of an improved electrochemical method for stimulating oil recovery from an underground oil-bearing formation;
[0011] [0011]FIG. 2 is a schematic diagram in partial sectional view of an apparatus with which the present method may be practiced; and
[0012] [0012]FIG. 3 is an elevational view of an electrode assembly adapted for use in practicing the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] Referring to the Figures in general, and to FIG. 1, specifically, the reference number 11 represents a subterranean formation containing crude oil. The subterranean formation 11 is an electrically conductive formation, preferably having a moisture content above 5 percent by weight. As shown in FIG. 1, formation 11 is comprised of a porous and substantially homogeneous media, such as sandstone or limestone. Typically, such oil-bearing formations are found beneath the upper strata of earth, referred to generally as overburden, at a depth of the order of 1,000 feet or more below the surface. Communication from the surface 12 to the formation 11 is established through spaced-apart boreholes 13 and 14 . The hole 13 functions as an oil-producing well, whereas the adjacent hole 14 is a special access hole designed for the transmission of electricity to the formation 11 .
[0014] The present invention can be practiced using a multiplicity of cathodes and anodes placed in vertical, horizontal or angular orientations and configurations. In FIG. 1, the system is shown having two electrodes installed vertically into the ground and spaced apart generally horizontally. A first electrode 15 is lowered through access hole 14 to a location in proximity to formation 11 . Preferably, first electrode 15 is lowered through access hole 14 to a medial elevation in formation 11 , as shown in FIG. 1. By means of an insulated cable in access hole 14 , the relatively positive terminal or anode of a high-voltage d-c electric power source 2 is connected to the first electrode 15 . The relatively negative terminal on the power source or cathode is connected to a second electrode 16 in producing well 13 , or within close proximity of the producing well. Between the electrodes, the electrical resistance of the connate water 4 in the underground formation 11 is sufficiently low so that current can flow through the formation between the first and second electrodes 15 , 16 . Although the resistivity of the oil is substantially higher than that of the overburden, the current preferentially passes directly through the formation 11 because this path is much shorter than any path through the overburden to “ground.”
[0015] To create the electric field, a periodic voltage is produced between the electrodes 15 , 16 . Preferably, the voltage is a DC-biased signal with a ripple component produced under modulated AC power. Alternatively, the periodic voltage may be established using pulsed DC power. The voltage may be produced using any technology known in the electrical art. For example, voltage from an AC power supply may be converted to DC using a diode rectifier. The ripple component may be produced using an RC circuit. Once the voltage is established, the electric current is carried by captive water and capillary water present in the underground formation. Electrons are conducted through the formation by naturally occurring electrolytes in the groundwater.
[0016] The electric potential required for carrying out electrochemical reactions varies for different chemical components in the oil. As a result, the desired intensity or magnitude of the ripple component depends on the composition of the oil and the type of reactions that are desired. The magnitude of the ripple component must reach a potential capable of oxidizing and reducing bonds in the oil components. In addition, the ripple component must have a frequency range above 2 hertz and below the frequency at which polarization is no longer induced in the formation. The waveshape of the ripple may be sinusoidal or trapezoidal and either symmetrical or clipped. Frequency of the AC component is preferably between 50 and 2,000 hertz. However, it is understood in the art that pulsing the voltage and tailoring the wave shape may allow the use of frequencies higher than 2,000 hertz.
[0017] A system suitable for practicing the invention is shown in FIG. 2. In this system, borehole 13 functions as an oil producing well which penetrates one region 17 of underground oil-bearing formation 11 . Well 13 includes an elongated metallic casing 18 extending from the surface 12 to the cap rock 23 immediately above region 17 . The casing 18 is sealed in the overburden 19 by concrete 20 as shown, and its lower end is suitably joined to a perforated metallic liner 24 which continues down into the formation 11 . Piping 21 is disposed inside the casing 18 where it extends from the casing head 22 to a pump 25 located in the liquid pool 26 that accumulates inside the liner 24 . Preferably the producing well 13 is completed in accordance with conventional well construction practice. The pump 25 is selected to operate at sufficient pumping head to draw oil from adjacent formation 11 up through metallic liner 24 .
[0018] Access hole 14 that contains first electrode 15 includes an elongated metallic casing 28 with a lower end preferably terminated by a shoe 29 disposed at approximately the same elevation as the cap rock 23 . The casing 28 is sealed in the overburden 19 by concrete 30 . Near the bottom of hole 14 , a tubular liner 31 of electrical insulating material extends from the casing 28 for an appreciable distance into formation 11 . The insulating liner 31 is telescopically joined to the casing 28 by a suitable crossover means or coupler 32 . Although shown out of scale in FIG. 2, liner 31 preferably has a substantial length and a relatively small inside diameter.
[0019] Below the liner 31 , a cavity 34 formed in the oil-bearing formation 11 contains the first electrode 15 . The first electrode 15 is supported by a cable 35 that is insulated from ground. The first electrode 15 is relatively short compared to the vertical depth of the underground formation 11 and may be positioned anywhere in proximity to the formation. Referring to FIG. 2, first electrode 15 is positioned at an approximately medial elevation within the oil-bearing formation 11 . The first electrode may be exposed to saline or oleaginous fluids in the surrounding earth formation, as well as a high hydrostatic pressure. Under these conditions, first electrode 15 may be subject to electrolytic corrosion. Therefore, the electrode assembly preferably comprises an elongate configuration mounted within a permeable concentric tubular enclosure radially spaced from the electrode body. The enclosure cooperates with the first electrode body to protect it from oil or other adverse materials that enter the cavity.
[0020] Referring now to FIG. 3, a preferred assembly for the first electrode 15 is shown. The assembly comprises a hollow tubular electrode body 15 electrically connected through its upper end to a conducting cable 35 and disposed concentrically in radially spaced relation within a permeable tubular enclosure 16 a of insulating material. The first electrode 15 is preferably coated externally with a material, such as lead dioxide, which effectively resists electrolytic oxidation. The assembly preferably includes means to place the internal surfaces of the first electrode 15 under pressure substantially equal to the external pressure to which the first electrode is exposed, thereby to preclude deformation and consequent damage to the first electrode. The enclosure 16 a is closed at the bottom to provide a receptacle for sand or other foreign material entering from the surrounding formation.
[0021] Referring again to FIG. 2, the first electrode 15 is attached to the lower end of insulated cable 35 , the other end of which emerges from a bushing or packing gland 36 in the cap 37 of casing 28 and is connected to the relatively positive terminal of an electric power source 38 . The other terminal on the electric power source 38 is connected via a cable 42 to an exposed conductor that acts as a second electrode 16 at the producing well 13 . The second electrode 16 may be a separate component installed in the proximity of producing well 13 or may be part of the producing well itself. In the embodiment shown in FIG. 2, the perforated liner 24 serves as the second electrode 16 , and the well casing 18 provides a conductive path between the liner and cable 42 .
[0022] Thus far, it has been presumed that electrodes 15 , 16 are located in a formation with a suitable moisture content and naturally occurring electrolytes to provide an electroconductive path through the formation. In formations that do not have adequate capillary and captive groundwater to be electrically conductive, an electroconductive fluid may be injected into the formation through one or both boreholes to maintain an electroconductive path between the electrodes 15 , 16 . Referring to FIG. 2, a pipe 40 in borehole 14 delivers electrolyte solution from the ground surface to the underground formation 11 . Preferably, a pump 43 is used to convey the solution from a supply 44 and through a control valve 45 into borehole 14 . Borehole 14 is preferably equipped with conventional flow and level control devices so as to control the volume of electrolyte solution introduced to the borehole. A detailed system and procedure for injecting electrolyte solution into a formation is described in the aforementioned U.S. Pat. No. 3,782,465. See also, U.S. Pat. No. 5,074,986, the entire disclosure of which is incorporated by reference herein.
[0023] Referring now to FIGS. 1 - 2 , the steps for practicing the improved method for stimulating oil recovery will now be described. An electric potential is applied to first electrode 15 so as to raise its voltage with respect to the second electrode 16 and region 17 of the formation 11 where the producing well 13 is located. The voltage between the electrodes 15 , 16 is preferably no less than 0.4 V per meter of electrode distance. Current flows between the first and second electrodes 15 , 16 through the formation 11 . Connate water 4 in the interstices of the oil formation provides a path for current flow. Water that collects above the electrodes in the boreholes does not cause a short circuit between the electrodes and surrounding casings. Such short circuiting is prevented because the water columns in the boreholes have relatively small cross sectional areas and, consequently, greater resistances than the oil formation.
[0024] As current is applied across formation 11 , electrolysis in the capillary water and captive water takes place. Water electrolysis in the groundwater releases agents that promote oxidation and reduction reactions in the oil. That is, negatively charged interfaces of oil compounds undergo cathodic reduction, and positively charged interfaces of the oil compounds undergo anodic oxidation. These redox reactions split long-chain hydrocarbons and multi-cyclic ring compounds into lighter-weight compounds, contributing to lower oil viscosity. Redox reactions may be induced in both aliphatic and aromatic oils. As viscosity of the oil is reduced through redox reactions, the mobility or flow of the oil through the surrounding formation is increased so that the oil may be drawn to the recovery well. Continued application of electric current can ultimately produce carbon dioxide through mineralization of the oil. Dissolution of this carbon dioxide in the oil further reduces viscosity and enhances oil recovery.
[0025] In addition to enhancing oil flow characteristics, the present invention promotes electrochemical reactions that upgrade the quality of the oil being recovered. Some of the electrical energy supplied to the oil formation liberates hydrogen and other gases from the formation. Hydrogen gas that contacts warm oil under hydrostatic pressure can partially hydrogenate the oil, improving the grade and value of the recovered oil. Oxidation reactions in the oil can also enhance the quality of the oil through oxygenation.
[0026] Electrochemical reactions are sufficient to decrease oil viscosities and promote oil recovery in most applications. In some instances, however, additional techniques may be required to adequately reduce retentive forces and promote oil recovery from underground formations. As a result, the foregoing method for secondary oil recovery may be used in conjunction with other prior art processes, such as electrothermal recovery or electroosmosis. For instance, electroosmotic pressure can be applied to the oil deposit by switching to straight d-c voltage and increasing the voltage gradient between the electrodes 15 , 16 . Supplementing electrochemical stimulation with electroosmosis may be conveniently executed, as the two processes use much of the same equipment. A method for employing electroosmosis in oil recovery is described in U.S. Pat. No. 3,782,465.
[0027] Many aspects of the foregoing invention are described in greater detail in related patents, including U.S. Pat. No. 3,724,543, U.S. Pat. No. 3,782,465, U.S. Pat. No. 3,915,819, U.S. Pat. No. 4,382,469, U.S. Pat. No. 4,473,114, U.S. Pat. No. 4,495,990, U.S. Pat. No. 5,595,644 and U.S. Pat. No. 5,738,778, the entire disclosures of which are incorporated by reference herein. Oil formations in which the methods described herein can be applied include, without limitation, those containing heavy oil, kerogen, asphaltinic oil, napthalenic oil and other types of naturally occurring hydrocarbons. In addition, the methods described herein can be applied to both homogeneous and non-homogeneous formations.
[0028] The terms and expressions which have been employed are used as terms of description and not of limitation. Although the present invention has been described in detail with reference only to the presently-preferred embodiments, there is no intention in use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof. It is recognized that various modifications of the embodiments described herein are possible within the scope and spirit of the invention. Accordingly, the invention incorporates variations that fall within the scope of the following claims. | A method is provided for recovering oil from a subterranean oil-bearing formation. One or more pairs of electrodes are inserted into the ground in proximity to a body of oil in said formation. A voltage difference is then established between the electrodes to create an electric field in the oil-bearing formation. As voltage is applied, the current is manipulated to induce oxidation and reduction reactions in components of the oil. The oxidation and reduction reactions lower the viscosity in the oil and thereby reduce capillary resistance to oil flow so that the oil can be removed at an extraction well. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a slate which may be used as a roofing slate, a tile or a panel for a wall, and also relates to a method of manufacturing therefor.
Conventionally, to give a pattern to a roof or a wall of a house, different colors of tiles or slates are combined.
According to this conventional method, it is necessary to prepare a number of tiles or slates which are different from each other in color. This method, therefore, brings about such a disadvantage that it necessitates different colors of paints and a plurality of metal molds which rise the manufacturing cost of the slate.
Therefore, it is desired such a slate and a method of manufacturing same which may give a pattern to a roof or a wall while minimizing a number of metal molds for manufacturing the slates.
The inventor has researched to be able to give a variation in color and pattern in spite of slating a house with a kind of slates on the assumption that it is used such a low-cost mortar slate of substantially a single color which may be easily molded by using a single colored mortar or which may be obtained easily by spraying a single color paint to a mold slate.
The inventor has paid attention to that a pattern or a color is determined by the wave length of a light which a viewer actually meets. It has been assumed that there would be a way of giving the viewer variation in pattern and color in case that reflecting conditions of a light on the slate are different partially, even if slates of single colored mortar are used other than using different colored slates.
SUMMARY OF THE INVENTION
An object of this invention is to obtain different colors and/or different pattern in spite of using slates of substantially a single colored mortar cement or a single color paint.
To achieve the first object, a slate of mortar cement having substantially a single color according to this invention comprises an outer surface with a first part having one shape and a second outer surface part having a shape different from the said first outer surface part for giving therebetween a color variation.
Therefore, since the outer surface of the slate is shaped to make a color variation, when the slate is, for example, used for a roof, the wave length of a light reflected upon the outer surface part is different from that of the light reflected upon the second outer surface part. Therefore, in spite of using the slates of single color, a variation in color or pattern can be obtained by arranging the slates in a desired pattern.
Another object of this invention is to give a color variation to a slate by forming inclined surface portions of different angles on the outer surface of the slate in spite of using a single color mortar cement or a single color paint.
Where such slates are used as a roof, a viewer on the ground sees the color of the slates, but actually receives the reflected wave lengths of the light which are affected by the inclined outer surfaces of different angles.
Namely, the viewer sees the color of the slate as a mixed color of that of the light reflected upon a standard surface and that of the light reflected upon the inclined surface. In carrying out the teaching of this invention, a standard surface is one which is parallel with the surface upon which the slate is to be mounted, and the inclined surface is sloped to have an angle relative to the surface upon which the slate is mounted and the standard surface. Thus, the viewer sees the slates with the color different from the original color thereof by the reason that the standard surface and the inclined surface reflect the light with different wave lengths though all of the outer surface of the slate is colored with a single color.
Accordingly, it may desirably obtain a variation in pattern and/or color by disposing the slates to take such positions that the standard surface and the inclined surface may form a desired pattern.
The color variation referred to in this invention is limited to a range of color variation which depends on intensity of the rays of the sun or the artificial light source and an angle of incidence to the slate. However, a number of color variations has been obtained in experiment more than the inventor expected.
The third object of this invention is to provide a method of manufacturing the above-mentioned slate.
The method of manufacturing the slate comprises the steps of combining at least two metal molds, molding a single color mortar cement into the metal molds, and forming an inclined surface portion or an irregular surface portion by means of press forming process.
In the course of the slate manufacturing, it has an advantage that combination of the metal molds can be varied so as to unlimitedly increase variations in color and pattern. Further, since it is possible to use many basic colors for the mortar cement, desired color patterns can be obtained easily.
Other objects and advantages of this invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show an embodiment of a slate according to this invention in which:
FIG. 1 is a front view of the whole slate,
FIG. 2 is a sectional view taken along lines II--II in FIG. 1,
FIG. 3 is an enlarged sectional view taken along lines III--III in FIG. 1, and
FIG. 4 is a front view showing a state of use of a number of the slates.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1 through FIG. 3, 1 is a slate which is manufactured by filling a mortar cement of single color such as green in metal molds (not shown) and by pressing same so as to form a standard outer surface portion 2, that is, the portion 2 has a constant thickness over its length and width and an inclined surface portion 3, which portion 3 relative to the outer surface portion 2 is inclined from an upper end 1A of the slate 1 to a bottom end 1B thereof at an angle of about 6 degrees to the standard surface portion 2. It is of course possible to spray a green paint to the slate after forming thereof. Thus, the slate is constructed such that the reflecting angles of the light upon the standard surface 2 and the inclined surface 3 become 30 degrees and 36 degrees respectively to a viewer on the ground when an angle of incidence to the slate is 30 degrees to the horizontal, in the event that the slate is fixed on a roof having an angle of inclination of about 40 degrees, as shown in FIG. 3.
It is preferable to use the angle of the inclined surface portion in the range of one to 10 degrees other than the above-mentioned 6 degrees, but it may be possible to use the other angles. The upper end 3A of the inclined surface portion 3 takes substantially the same level as the standard surface portion SB.
The bottom end SB of the inclined surface portion 3 is located at a middle portion between the upper and lower portions of the slate 1. The standard surface portion 2 is formed aventurine or rough and the inclined surface portion S is formed even or flat so as to increase color variations by utilizing intensity of reflection of the light due to interference of the light with the rough surface portion 2. To this end, the interior wall of the metal mold which forms the standard surface portion 2 of the outer surface of the slate 1, is made rough and that of the metal mold for the inclined surface portion 3 is finished flat. The metal molds referred to in this invention is made of not only metal but also wood or plastics.
FIG. 4 shows an example of the arrangement of the slates for slating a roof.
Improvements of this invention may be cited as follows:
It is possible to form the standard surface portion 2 to be aventuring by means of embossment other than forming of the uneven or rough surface portion.
It is also possible to arrange the standard surface 2 and the inclined surface S to disperse at plural positions of the single slate 1.
In case that a color paint is sprayed on a single slate 1, it is of course possible to achieve the object of this invention even if plural color paints are used as far as the idea of this invention is utilized.
It is preferable to arrange normal slates and the slates of this invention desirably so as to make many kinds of patterns.
To achieve the object of this invention, the following modification can be made.
Instead of the inclined surface of the slate, a part of the outer surface of the slate is formed to have a brilliant spangled appearance of aventurin and the other part is formed flat and smooth, so that a color variation can be obtained by strength and weakness of reflection of the light occurred by interference on the surface having a brilliant spangled appearance of aventurin. To manufacture the slate, the interior wall surface of a metal mold (not shown) which forms the part of the outer surface of the slate, is made rough or to have a brilliant spangled appearance of aventurin and the interior wall surface of the other metal mold (not shown) is finished flat and smoothly. The mold used in this invention may be made by not only metal but also wood, plastics and the like. These molds are assembled and the mortar cement of single color 4 is injected therein so as to manufacture the slate 1. Where these slates 1 are arranged as roof slates, a pattern appears due to contrast between interference colors upon the rough or brilliant spangled appearance of an aventurin surface and the color produced by normal reflection of the light upon the smooth standard surface, when a viewer sees the roof far from same. | A slate and the method of manufacturing therefor comprising substantially a single color mortar cement. The outer surface of the slate has at least two different shapes which produce a different color variation to one another. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a bag-making, filling and packing apparatus. More particularly, the invention relates to a discharge device for a bag-making, filling and packing apparatus provided with a bag-making cylinder around which packing film is wound for making a packing bag and through which cylinder commodity articles are filled in the bag after the bag is lowered.
2. Description of the Prior Art
In order to fill in the bag with commodity articles by means of the above-type apparatus, certain time is required for the articles to fall down through the bag-making cylinder. The filling time required is not short. For overcoming this problem, if a cover is provided at the bottom of the cylinder and if additional articles are made to fall down to the cover as the first bag is sealed, the filling time is only the falling time from the cover to the bag and thus the time is shortenend.
In the case where the commodity articles comprise a powder material, a screw conveyor is provided in the bag-making, filling an packing apparatus. Powdered commodity is conveyed and filled in the bag if the screw conveyor is rotated to a predetermined angle. If the conveyor is stopped, an irregular amount of powder will fall down and scatter. If, in this case, a cover is provided at the discharge below the cylinder, such trouble can be prevented.
As is clear from the explanation above, it is advantageous to provide a cover or covers at the discharge below or at the botom of the cylinder. However, the discharge is closed by the bag and the space for the discharge is too narrow to be provided with a mechanism for opening and closing the cover. Therefore, even if the mechanism is provided at the discharge, it does not function well and requires maintenance cost. Moreover, the mechanism of prior art is expensive.
SUMMARY OF THE INVENTION
It is an inherent object of the invention to provide a discharge device which functions well and minimizes the maintenance cost, and which can be assembled at low cost.
The object above is accomplished by providing covers at the discharge of the bag-making cylinder and by providing the mechanism for opening and closing the covers outside the bag.
Specifically, the discharge apparatus of the invention is provided with a mechanism for opening and closing the covers, which consists of openable covers having respective magnet or permanent magnet bodies and of magnets at the position outside the produced bag, and which is operated to open and close the covers by changing the magnet field of these magnets.
The magnet field is changed by the magnets' movement toward and away from each other. The discharge is provided at the bottom end of the cylinder, or at the bottom end of the screw conveyor if the conveyor is provided in the cylinder.
In order that the invention may be more clearly understood, preferred embodiments will be described, by way of example, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a front view, partly cut out, of the first embodiment of the invention;
FIG. 2 is an enlarged front view of the main part of the first embodiment;
FIG. 3 is an enlarged sectional view along the line (III)--(III) of FIG. 2;
FIG. 4 is a front view, partly cut away, of a second embodiment of the invention;
FIG. 5 is an enlarged front view of the main part of the second embodiment;
FIG. 6 is a sectional view of a mechanism for opening and closing covers in a third embodiment according to the invention; and
FIGS. 7 and 8 show sectional views similar to FIGS. 3 and 6 of fourth and fifth embodiments of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIGS. 1 through 3, which illustrate the first embodiment of the invention, a bag-making cylinder 1 is provided with a number of air holes 1a, 1a, and packing film B is wound around the cylinder.
The air holes 1a act to discharge air so as to avoid the situation where covers 3, 3 may not open due to air in the bag when articles of commerce have been put into the cylinder 1. The holes are inclined upwardly to the direction outside the cylinder surface so that articles may not escape therethrough.
The hopper 11 for receiving articles and a sailor device 10 for making package film B cylindrical are provided at the upper part of the bag-making cylinder 1. Further, a sealing device 12 for longitudinally sealing the film B and thus for giving it a cylindrical form are detachably provided to the cylinder.
At two sides of the cylinder are detachably provided feeding belts 13, 13 for feeding the film downwardly. A crosswise sealing device 4 having a cutter is openably provided below the cylinder.
The crosswise sealing device 4 seals the opening part of a first bag A 1 and the bottom of a second bag A 2 crosswise. Further, the cutter separates the former bag A 1 from the latter A 2 .
The bottom of the cylinder is opened V shape in cross section and is provided with openable covers 3, 3.
The covers 3, 3 consist of steel plates of substantially half-oval shape and can be opened by means of hinges 3a, 3a. A coil spring 3b engages with each of the respective covers so that the covers can be closed thereby.
A mechanism for opening and closing the cover 3 is explained with reference to FIG. 3. A guide bar 5 is provided at respective sides of the cover 3. The guide bar has a sliding member 6. A permanent magnet 8 is mounted to the member 6 by means of a fitting member 7.
A rotating member 9 consisting of three arms 9b, 9c and 9d, rotates arounds a rotary shaft 9a. Each arms are connected to an air cylinder 14 and to the sliding member 6.
When the air cylinder 14 reciprocates, the three arms 9b, 9c and 9d rotate. As a result, the permanent magnet 8 moves via the sliding member 6.
The magnetic field generated by the magnet 8 is strong enough to act on the cover 3. The cover opens or closes in synchronism with the movement of the magnet 8.
Next, the operation of the apparatus is explained with reference to the drawings.
Package bag film B is wound around the bag-making cylinder 1 by a sailor device 10. The film is sealed cylindrical around the cylinder by the vertical sealing device 12, and bags A 1 , A 2 produced from the film are feed downward by feeding belts 13, 13.
Then the crosswise sealing device 4 is closed and seals the bottom of later bag A 2 and the upper opening of former bag A 1 while it cuts the bag A 1 from the bag A 2 . Then the device 4 is opened.
Thereafter the air cylinder 14 is operated so as to open the magnet 8 for opening the cover 3. After one or more articles of commerce are filled in the bag, the air cylinder 14 is operated to counter direction so as to close the cover 3.
Then the feeding belts 13, 13 are operated to feed bags A 1 , A 2 downward. While the bags are sealed crosswise, the next articles are received through the hopper 11 and stored on covers 3, 3. The procedure mentioned above is repeated.
Next, the other embodiments are explained except for similar structures of which references show same structures of the first embodiment.
The second embodiment directed to a bag-making filling and packaging apparatus for powder material for commerce, is explained with reference to FIGS. 4 and 5. A screw conveyor 2 is provided concentrically in a bag-making cylinder 1. The conveyor 2 consists of a pipe 2b and a screw shaft 2a housed in the pipe 2b. When the shaft 2a is rotated to a certain angle, a desired amount of powder falls down into a bag A 2 .
The bottom of the pipe 2b is made substantially V in cross section and is provided with covers 3, 3. The structure of the cover and its opening and closing mechanism are identical to those of the first embodiment.
As has been explained above, the apparatus of the invention is applicable also to that for bags of powdered material.
The third embodiment is explained with reference to FIG. 6 which illustrates a variation of the opening and closing mechanism. Specifically, the mechanism consists of two electric magnets 8', 8' fixed to positions outside covers 3, 3. When the magnets are "ON" position, the covers are attracted to respective magnets and become open, while covers close due to the action of twisted coil spring 3b when the magnets are on "OFF" position. The operation of the third embodiment is identical to that of the first embodiment and is not explained.
Since mechanisms such as an air cylinder used in the first embodiment is not necessary for this embodiment, a simpler and inexpensive structure can be realized.
In all the explained embodiments, the pulling forces of the magnets are utilized, however, the repulsion forces of the magnets may be used as well.
For example, as shown in FIGS. 7 and 8, a magnet plate 3c is applied to each of covers 3, 3 in place of the twisted coils 3b, 3b used in the third embodiment, and if magnetic pole of the same polarity is generated in electromagnets 8', 8', the covers will be closed due to repulsion forces when the electronic magnets 8', 8' are operated to be in an "ON" position, and will be opened due to the covers' own weight in an "OFF"position.
As is clear from the explanation above, the opening and closing mechanism can be easily attached to covers. Even if troubles occur in the device, the bags will not be broken and articles or powders in the bag will not be scattered. Therefore, the discharge device can be repaired easily and its maintenance is effected smoothly.
It is further understood by those skilled in the art that the foregoing description is that of preferred embodiments of the disclosed outlet device for bag-making filling and packing apparatus and that various changes and modifications may be made in the invention without departing from the spirit and scope thereof. | A discharge device for a bag-making, filling and packing apparatus which consists of a bag-making cylinder around which packing film is wound for making a bag and through which commodity article is filled in the bag after the bag is feeded to the lower position consists of magnets for opening and closing movable covers which are provided at the discharge end of the bag-making cylinder. The magnets can be permanent magnets which are movable toward and away from the covers or electromagnets which are stationarily mounted adjacent the covers. | 1 |
BACKGROUND
1. Technical Field
The present invention relates to a lens, especially for modifying light beam of a LED configured on a bottom recess of the lens.
2. Description of Related Art
FIG. 1 is a prior art.
U.S. Pat. No. 7,254,309 discloses a lens for a LED, the light emitted from the LED chip 40 enters the lens 20 through the incident surface 22 . A portion of the light is reflected by the reflective surface 23 to the second refractive surface 32 in an internal total reflection manner, and then the light is refracted by the second refractive surface 32 and emits out of the second refractive surface 32 of the lens 20 along a lateral direction of the lens 20 , such as a first optical path P 1 of the lens 20 . The other portion of the light enters the lens 20 through the incident surface 22 and then directly emits out of the lens 20 to toward the lateral directions of the lens 20 respectively to be refracted by the first refractive surface 31 along a second optical path P 2 and the third refractive surface 33 along a third optical path P 3 . The first optical path P 1 , the second optical path P 2 and the third optical path P 3 are in a direction substantially normal to the central optic axis C of the lens 20 . Hence the light emitted from the LED chip 40 is directed towards a lateral direction of the lens 20 .
After the light emitted from the LED chip 40 enters the lens 20 , the intensity distribution of energy of the emitted light can be divided in a zone 1 , a zone 2 and a zone 3 . The zone 1 is located between the central optic axis C and the connection line of the first cross point c 1 to the second cross point c 2 . The zone 2 is located between the connection line of the first cross point c 1 to the fourth cross point c 4 and the zone 1 (the third cross point c 3 is located on the connection line of the first cross point c 1 to the fourth cross point c 4 ). The zone 3 is located between the zone 2 and the bottom surface 21 . The energy distribution is strongest in the zone 1 , then sub-strong in the zone 2 , and weakest in the zone 3 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art.
FIGS. 2-3 are a first lens according to the present invention.
FIGS. 4-5 are a second lens according to the present invention.
FIGS. 6-7 are a third lens according to the present invention.
FIGS. 8-9 are a fourth lens according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Total internal Reflection (TIR) is an optical phenomenon that occurs when a light beam strikes a medium boundary at an angle larger than the Critical Angle with respect to the normal to the surface. If the Refractive Index is lower on the other side of the boundary no light can pass through, so effectively all of the light is reflected. The critical angle is the Angle of Incidence above which the total internal reflection occurs.
When a light beam crosses a boundary between materials with different refractive indices, the light beam will be partially refracted at the boundary surface according to the Snell's Law, and partially reflected. The Snell's law gives the relationship between angles of incidence and refraction for a wave impinging on an interface between two media with different indices n 1 , n 2 of refraction:
n 1 sin Θ 1 =n 2 sin Θ 2
where Θ 1 and Θ 2 are the angles from the normal of the incident and refracted waves, respectively.
However, if the angle of incidence is greater (i.e. the ray is closer to being parallel to the boundary) than the critical angle—the angle of incidence at which light is refracted such that it travels along the boundary, where the Θ 2 equals 90 degree, then the light will stop crossing the boundary altogether and instead totally reflect back internally.
FIGS. 2-3 are a first lens according to the present invention.
FIG. 2 shows a section view of the first lens 501 . Lens 501 has four total internal reflection surfaces. A first total internal reflection surface 511 is configured in a first angle A 1 with respect to a longitudinal axis C of the lens 501 . A second total internal reflection surface 512 is neighbored to the first total internal reflection surface 511 and configured in a second angle A 2 larger than the first angle A 1 with respect to the longitudinal axis C of the lens 501 . A third total internal reflection surface 513 is neighbored to the second total internal reflection surface 512 and configured in a third angle A 3 larger than the second angle A 2 with respect to the longitudinal axis C of the lens 501 . A fourth total internal reflection surface 514 is neighbored to the third total internal reflection surface 513 and configured in a fourth angle A 4 larger than the third angle A 3 with respect to the longitudinal axis C of the lens 501 .
Further, FIG. 2 shows that an exiting surface 515 is a flat surface, neighbored to the fourth total internal reflection surface 514 .
A bottom recess 520 is configured on the bottom of the lens 501 . A LED 40 is configured in the recess 520 . A top incident surface 521 is configured on a top of the recess 520 , and a side incident surface 522 encloses the recess 520 . A first portion of the light beams L 51 , L 52 , L 53 of the LED 40 enters the top incident surface 521 and then reflected by one of the total internal reflection surface 511 , 512 , 513 , 514 and exits from the exiting surface 515 . A second portion of the light beams L 54 of the LED 40 enters the side incident surface 522 to be refracted and then exits from the exiting surface 515 . FIG. 2 shows that the top incident surface 521 is made a convex surface against the recess 520 in this embodiment.
FIG. 3 shows a section view of an illumination intensity profile of the lens of FIG. 2 . The illumination intensity profile 501 D is mainly projected to the right top and left top of the lens 501 in the section view, however the illumination intensity profile 501 D is of a bowl-shaped profile in a three dimensional configuration.
FIGS. 4-5 are a second lens according to the present invention.
FIG. 4 shows a section view of the second lens according to the present invention. The key feature of this embodiment is that the exiting surface 515 R is roughened to a certain status so that each and all exiting light beam is firstly diffused and then emitted softly and broadly. FIG. 4 shows diffused beam intensity profile LS 51 , LS 52 existed from a spot S 51 , S 52 . The LS 51 shows a light intensity distribution of the light beam exits from the spot S 51 . The LS 52 shows a light intensity distribution of the light beam exits from the spot S 52 . The light intensity distribution LS 51 , LS 52 is softer as compared with the light intensity of L 51 , L 52 of FIG. 2 respectively. The light intensity L 51 , L 52 in FIG. 2 is a single light beam or a very narrow bunch of light beam.
FIG. 5 shows a section view of an illumination intensity profile of the lens of FIG. 4 . The light beam is projected softly, evenly, and broadly to the right side and left side of the lens 502 in the section view, however the illumination intensity profile 502 D is of a donut-shaped profile in a three dimensional configuration.
FIGS. 6-7 are a third lens according to the present invention.
FIG. 6 shows a section view of the third lens. As compared to the one shown in FIG. 3 the key feature of FIG. 6 is that the exiting surface is a bent surface 515 A, 515 B. The lens 503 has four total internal reflection surfaces 511 ˜ 514 similar to the one shown in FIG. 2 .
FIG. 6 shows a section view of the lens 503 . Lens 503 has a first total internal reflection surface 511 , configured in a first angle A 1 with respect to a longitudinal axis C of the lens 503 . A second total internal reflection surface 512 is neighbored to the first total internal reflection surface 511 and configured in a second angle A 2 larger than the first angle A 1 with respect to the longitudinal axis C of the lens 503 . A third total internal reflection surface 513 is neighbored to the second total internal reflection surface 512 and configured in a third angle A 3 larger than the second angle A 2 with respect to the longitudinal axis C of the lens 503 . A fourth total internal reflection surface 514 is neighbored to the third total internal reflection surface 513 and configured in a fourth angle A 4 larger than the third angle A 3 with respect to the longitudinal axis C of the lens 503 .
A first exiting surface 515 A is neighbored to the fourth total internal reflection surface 514 and configured in a fifth angle A 5 larger than the fourth angle A 4 with respect to the longitudinal axis C of the lens 503 . A second exiting surface 515 B is neighbored to the first exiting surface 515 A and configured in a sixth angle A 6 larger than the fifth angle A 5 with respect to the longitudinal axis C of the lens 503 .
A bottom recess 520 is configured on the bottom of the lens 503 , a LED 40 is configured in the recess 520 . A top incident surface 521 is configured on a top of the recess 520 , and a side incident surface 522 encloses the recess 520 . A first portion of the light beams L 51 , L 52 of the LED 40 enters the top incident surface 521 and then reflected by one of the total internal reflection surface 511 , 512 , 513 , 514 and exits from the exiting surface 515 A. A second portion of the light beams L 54 , L 55 of the LED 40 enters the side incident surface 522 to be refracted and then exits from the exiting surface 515 B. The top incident surface 521 is made a convex surface in this embodiment.
FIG. 7 shows a section view of an illumination intensity profile of the lens of FIG. 6 . The illumination intensity profile 503 D is mainly projected to the right top and left top of the lens 503 in the section view, however the illumination intensity profile 503 D is with a relative stronger light intensity on top portion and a relative lower light intensity on bottom portion.
FIGS. 8-9 are a fourth lens according to the present invention.
FIG. 8 shows a section view of the fourth lens according to the present invention. The key feature of this embodiment is that the exiting surface 515 AR, 515 BR is roughened so that each and all exiting light beam is firstly diffused and then emitted softly and broadly. FIG. 8 shows diffused beam is exited from spots S 511 , S 522 as an example. The LS 511 shows a light intensity distribution of the light beam exits from the spot S 511 . The LS 512 shows a light intensity distribution of the light beam exits from the spot S 512 . The light intensity distribution LS 511 , LS 512 is softer as compared with the light intensity of L 51 , L 52 of FIG. 6 respectively. The light intensity L 51 , L 52 in FIG. 6 is a single light beam or a very narrow bunch of light beam.
FIG. 9 shows a section view of an illumination intensity profile of the lens of FIG. 8 . The light beam is projected softly, evenly, and broadly to the right side and left side of the lens 504 in the section view, however the illumination intensity profile 504 D is of a donut-shaped profile in a three dimensional configuration.
While several embodiments have been described by way of example, it will be apparent to those skilled in the art that various modifications may be configured without departing from the spirit of the present invention. Such modifications are all within the scope of the present invention, as defined by the appended claims. | A side illumination lens for a LED is disclosed. One of the embodiments includes a bottom cavity, an incident surface, four total internal reflective surfaces, and a side refractive surface. Light beam emitted by the LED enters the lens through the incident surface. A first portion of the light beam is reflected by the total internal reflection surfaces to the refractive surface and emits out of the lens. The second portion of light beam enters the lens and exits from the refractive surface. A second one of the embodiments is to roughen the side refractive surface for diffusing the exit light beams so that a broader area can be illuminated softly. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 10/785,239 filed Feb. 23, 2004, which claims the benefit of priority from Korean Patent Application No. 10-2003-19597 filed Mar. 28, 2003 and Korean Patent Application No. 10-2003-20598 filed Apr. 1, 2003, the contents of which are herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an LCD (Liquid Crystal Display) apparatus and a method of manufacturing the same, and more particularly to an LCD apparatus having an improved display quality and a method of manufacturing the same.
2. Description of the Related Art
Today, touch screen technologies are widely applied to electronic instruments such as a PDA (Personal Digital Assistants) or a mobile communication device.
In a touch screen LCD apparatus, a ripple phenomenon sometimes appears on the LCD panel when a user touches a surface of the LCD panel. This ripple phenomenon, which is highly undesirable, is caused by swelling of the liquid crystal when the user repeatedly touches a certain area on the surface of the LCD panel.
In an attempt to prevent the ripple phenomenon, a column spacer has been formed inside the LCD panel to support the surface that is touched during use. However, since the column spacer is uniformly distributed inside the LCD panel, use of these spacers is often accompanied by loss of efficiency/quality in other aspects, such as image quality. This is because the occurrence and the extent of the LCD panel deformation varies depending on the location of the panel that is touched by the user even if the user touches the different locations at the same force.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an LCD apparatus having an improved display quality, and a method suitable for manufacturing the above LCD apparatus.
The invention includes a light emitting apparatus that includes 1) a first substrate having a first region that substantially transmits light and a second region that substantially intercepts light, 2) a second substrate attached to the first substrate so as to form a cell gap of a predetermined distance between the first and the second substrates, 3) a liquid crystal layer positioned in the cell gap, and 4) a spacer positioned between the first substrate and the second substrate in the second region so as to maintain the cell gap substantially without blocking light that is not intercepted by the second region. By forming the spacer near a the second region that substantially intercepts light, the spacer does not cause further loss of light or decrease of opening ratio. At the same time, by positioning the spacers between the first and the second substrates, thereby providing extra support to the light emitting apparatus when it is used as a touch screen device, the spacers will reduce the undesirable ripple effect.
The invention also includes the method of making the above light emitting apparatus. The method includes 1) obtaining a first substrate having a first region that substantially transmits light and a second region that substantially intercepts light, 2) attaching a second substrate to the first substrate so as to form a cell gap of a predetermined distance between the first and the second substrates, 3) filing the cell gap with liquid crystal, and 4) forming a spacer between the first and the second substrates to maintain the cell gap substantially without blocking light that is not intercepted by the second region, wherein the spacer is located in the second region. Since the spacer is located in the second region, it provides support to the display panel without blocking significant amount of light.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other advantages of the present invention will become readily apparent by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
FIG. 1 is a plan view showing a lower substrate of an LCD apparatus according to an exemplary embodiment of the present invention;
FIG. 2 is a cross-sectional view showing a transmissive type LCD apparatus having the lower substrate shown in FIG. 1 ;
FIG. 3 is a cross-sectional view showing a transmissive type LCD apparatus according to another exemplary embodiment of the present invention;
FIG. 4 is a plan view showing a lower substrate of an LCD apparatus according to another exemplary embodiment of the present invention;
FIG. 5 is a cross-sectional view showing a transmissive type LCD apparatus having the lower substrate shown in FIG. 4 ;
FIG. 6 is a cross-sectional view showing a transmissive type LCD apparatus according to another exemplary embodiment of the present invention;
FIG. 7 is a cross-sectional view showing a transflective type LCD apparatus according to another exemplary embodiment of the present invention;
FIG. 8 is a cross-sectional view showing a transflective type LCD apparatus according to another exemplary embodiment of the present invention;
FIG. 9 is a cross-sectional view showing a reflective LCD apparatus according to another exemplary embodiment of the present invention;
FIG. 10 is a cross-sectional view showing a reflective type LCD apparatus according to another exemplary embodiment of the present invention; and
FIGS. 12A to 12F are views illustrating a method of manufacturing an LCD apparatus according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, a “first member” refers to a first substrate and any peripheral layers deposited on the first substrate, and a “second member” refers to a second substrate and any peripheral layers deposited thereon. Specifically, a “second member 1000 ” includes a second substrate 100 . A “spacer,” as used herein, is any structure or mechanism used to form or maintain a cell gap between the first and the second members, and is not limited to a particular material, shape, or size.
FIG. 1 is a plan view showing a member (second member) of an LCD apparatus according to an exemplary embodiment of the present invention. FIG. 2 is a cross-sectional view showing a transmissive type LCD apparatus having the second member of FIG. 1
Referring to FIGS. 1 and 2 , a transmissive type LCD apparatus 2000 includes a second member 1000 , a first member 200 and a liquid crystal layer 400 interposed between the first and second members 1000 and 200 .
The second member 1000 includes a plurality of pixels arranged in a matrix configuration. In this exemplary embodiment, a pixel positioned at a position of M column by N row, where N is a natural number greater than 2 and N is a natural number greater than 1, will be described. The pixel includes a (M−1)-th gate line 145 , Mth gate line 131 , Nth data line 230 a , a TFT 300 and a pixel electrode 420 .
A gate pattern is formed on a second substrate 100 . The gate pattern includes the (M−1)-th gate line 145 extending in a first direction D 1 , the Mth gate line 131 extending in the first direction D 1 and a gate electrode 110 branching from the Mth gate line 131 . In this exemplary embodiment, the (M−1)-th gate line 145 is operated as a first auxiliary electrode 150 of an auxiliary capacitor Cst described below.
The gate pattern includes a conductive material such as aluminum (Al), aluminum alloy, molybdenum (Mo), molybdenum-tungsten alloy (MoW), chromium (Cr), or tantalum (Ta). The gate pattern may consist of a single layer, a double layer or a triple layer. In an exemplary case where the gate pattern is provided with double or triple layers, one layer includes the chromium (Cr) or the aluminum (Al) and another layer includes the aluminum (Al) or the molybdenum (Mo).
A gate insulating layer 170 is formed over the second substrate 100 comprising a silicon nitride (SiN x ) on which the gate pattern is formed. A semiconductor layer 320 and an ohmic contact layer 330 are formed on the gate insulating layer 170 near the gate electrode 110 .
A data pattern is formed on the gate insulating layer 170 on which the ohmic contact layer 330 is formed. The data pattern includes the Nth data line 230 a extending in a second direction D 2 substantially perpendicular to the first direction D 1 , a source electrode 210 branching from the Nth data line 230 a and a drain electrode 310 spaced apart from the source electrode 210 in a predetermined distance. The data pattern further includes a second auxiliary electrode 230 b formed on the second substrate 100 and the gate insulating layer 170 and overlying the first auxiliary electrode 150 .
Accordingly, the TFT 300 having the gate electrode 110 , gate insulating layer 170 , semiconductor layer 132 , ohmic contact layer 133 , source electrode 210 and drain electrode 310 is formed on the second substrate 100 . Also, the auxiliary capacitor Cst having the first and second auxiliary electrodes 150 and 230 b is formed on the second substrate 100 .
An organic layer 370 including a poly-benzocyclobutene and an acrylic resin is formed over the second substrate 100 on which the data pattern is formed. The organic layer 370 is patterned through a photolithography process, so that first and second contact holes 710 and 810 are formed at the organic layer 370 , exposing the drain electrode 310 and the second auxiliary electrode 230 b , respectively. The pixel electrode 420 is electrically connected to the drain electrode 310 through the first contact hole 710 and electrically connected to the second auxiliary electrode 230 b through the second contact hole 810 .
The pixel electrode 420 includes a transparent conductive material, such as indium tin oxide (hereinafter, referred to as ITO), so as to transmit light provided from a direction of the second member 1000 . The pixel electrode 420 is overlaps a part of the (M−1)-th gate line 145 but does not overlap the Nth data line 230 a and the Mth gate line 131 , as illustrated in FIG. 1 .
The first member 200 includes a common electrode 240 positioned on the surface that is closest to the liquid crystal layer 400 . The common electrode 240 includes ITO. The common electrode 240 operates as a liquid crystal capacitor Clc with the liquid crystal layer 400 and pixel electrode 420 . The auxiliary capacitor Cst is electrically connected to the liquid crystal capacitor Clc by connecting the second auxiliary electrode 230 b to the pixel electrode 420 .
Due to a parasitic capacitance that appears between the gate and source electrodes 110 and 210 of the TFT 300 , in general, a voltage signal applied to the pixel electrode 420 may be distorted. The distorted voltage signal is herein referred to as “kickback voltage.” The kickback voltage sometimes causes a flicker in the transmissive type LCD apparatus 2000 .
In this exemplary embodiment, since the transmissive type LCD apparatus 2000 includes the auxiliary capacitor Cst electrically connected to the liquid crystal capacitor Clc, the transmissive type LCD apparatus 2000 may reduce the kickback voltage and increase a voltage holding ratio of the liquid crystal capacitor Clc, thereby improving a display quality thereof.
In order to uniformly maintain a cell gap between the first and the second members 200 and 1000 , the transmissive type LCD apparatus 2000 includes a column spacer 440 a disposed between the first and second members 200 and 1000 . The column spacer 440 a is formed by depositing an organic layer on the common electrode 240 of the first member 200 and patterning the organic layer.
The column spacer 440 a is formed on a non-effective display area. As used herein, an area on which the auxiliary capacitor Cst is formed is referred to as the “non-effective display area.” The reason this area is referred to as the “non-effective display area” is that light from a light source (not shown), such as a backlight assembly disposed under the second member 1000 , is intercepted by the first and second auxiliary electrodes 150 and 230 b . The second auxiliary electrode 230 b and a lower portion of the column spacer 440 a is received in the second contact hole 810 , so that the column spacer 440 a makes contact with the pixel electrode 420 disposed on the second auxiliary electrode 230 b.
By forming the column spacer 440 a on the non-effective display area, any reduction in the opening ratio of the transmissive type LCD apparatus 2000 due the presence of the column spacer 440 a can be avoided. Also, the column spacer 440 a prevents the first member 200 from being pushed down toward the second member 1000 , for example while being used as a touch screen panel.
FIG. 3 is a cross-sectional view showing a transmissive type LCD apparatus according to another exemplary embodiment of the present invention. In FIG. 3 , the same reference numerals denote the same elements in FIG. 2 , and thus the detailed descriptions of the same elements will be omitted.
Referring to FIGS. 1 and 3 , a transmissive type LCD apparatus 3000 includes a column spacer 440 a disposed between a first member 200 and a second member 1000 so as to uniformly-maintain a constant cell gap between the members. The column spacer 440 a is formed by depositing an organic layer (not shown) on a common electrode 240 of the first member 200 and patterning the organic layer.
The column spacer 440 a is formed in the non-effective display area on which an auxiliary capacitor Cst makes contact with a pixel electrode 420 disposed on an organic layer 370 .
As described above, any reduction in the opening ratio of the transmissive type LCD apparatus 2000 due the presence of the column spacer 440 a can be avoided by forming the column spacer 440 a in the non-effective display area. Also, the column spacer 440 a prevents the first member 200 from being pushed down toward the second member 1000 , for example while being used as a touch screen panel.
FIG. 4 is a plan view showing a second substrate of an LCD apparatus according to another exemplary embodiment of the present invention. FIG. 5 is a cross-sectional view showing a transmissive type LCD apparatus having the second member shown in FIG. 4 .
Referring to FIGS. 4 and 5 , a transmissive type LCD apparatus 6000 includes an alternative second member 5000 , a first member 200 and a liquid crystal layer 400 interposed between first and second members 200 and 5000 .
The alternative second member 5000 includes a plurality of pixels arranged in a matrix configuration. Each of the pixels includes a gate line 130 a , a data line 230 , an auxiliary electrode line 130 b , a TFT 300 and a pixel electrode 420 .
A gate pattern is formed on an second substrate 100 . The gate pattern includes the gate line 130 a , the auxiliary electrode line 130 b , and a gate electrode 110 of the TFT 330 branching from the gate line 130 a . In this exemplary embodiment, the auxiliary electrode line 130 b is operated as a first auxiliary electrode 140 of an auxiliary capacitor Cst described below. The auxiliary electrode line 130 b is extended in a same direction as that of the gate line 130 a.
A gate insulating layer 170 is formed over the second substrate 100 on which the gate pattern is formed. A semiconductor layer 320 and an ohmic contact layer 330 are successively formed on the gate insulating layer 170 corresponding to the gate electrode 110 .
A data pattern is formed on the gate insulating layer 170 on which the semiconductor layer 320 and ohmic contact layer 330 are formed. The data pattern includes the data line 230 a , a source electrode 210 branched from the data line 230 a , and a drain electrode 310 spaced apart from the source electrode 210 in a predetermined distance. The drain electrode 315 is formed on the gate insulating layer 170 , and extends so as to overlap the auxiliary electrode line 130 b and operate as a second auxiliary electrode 313 of the auxiliary capacitor Cst.
Thus, the auxiliary capacitor Cst having the first auxiliary electrode 140 of the auxiliary electrode line 130 b and the second auxiliary electrode 313 extending from the drain electrode 315 is completely formed on the second substrate 100 .
The alternative second member 5000 includes an organic layer 370 through which a contact hole 800 is formed so as to expose the second auxiliary electrode 313 . A pixel electrode 410 is formed on the second auxiliary electrode 313 exposed through the contact hole 800 and the organic layer 370 . The pixel electrode 410 is electrically connected to the second auxiliary electrode 313 through the contact hole 800 and also electrically connected to the drain electrode 315 since the second auxiliary electrode 313 is an extension of the drain electrode 315 .
The first member 200 includes a common electrode 240 positioned on the surface that is closest to the liquid crystal layer 400 . The common electrode 240 operates as a liquid crystal capacitor Clc with the liquid crystal layer 400 and pixel electrode 420 . The auxiliary capacitor Cst is electrically connected to the liquid crystal capacitor Clc by connecting the second auxiliary electrode 313 to the pixel electrode 420 .
In this exemplary embodiment, since the transmissive type LCD apparatus 6000 includes the auxiliary capacitor Cst electrically connected to the liquid crystal capacitor Clc, the transmissive type LCD apparatus 6000 reduces the kickback voltage and increases a voltage holding ratio of the liquid crystal capacitor Clc, thereby improving the display quality.
In order to uniformly maintain a cell gap between the first and second members 200 and 5000 , the transmissive type LCD apparatus 6000 includes a column spacer 430 a disposed between the first and second members 200 and 5000 . The column spacer 430 a is formed on a non-effective display area on which the second auxiliary electrode 313 is received in the contact hole 800 , so that the column spacer 430 a makes contact with the pixel electrode 420 disposed on the second auxiliary electrode 313 .
That is, the light provided from a light source (not shown), such as a backlight assembly disposed under the alternative second member 5000 , is intercepted by the first and second auxiliary electrodes 140 and 313 . Thus, an area on which the auxiliary capacitor Cst is formed is a non-effective display area.
As described above, any reduction in the opening ratio of the transmissive type LCD apparatus 6000 due to the presence of the column spacer 430 a can be avoided by forming the column spacer 430 a in the non-effective display area. Also, the column spacer 430 a prevents the first member 200 from being pushed down toward the alternative second member 5000 .
FIG. 6 is a cross-sectional view showing a transmissive type LCD apparatus according to another exemplary embodiment of the present invention. In FIG. 6 , the same reference numerals denote the same elements in FIG. 5 , and thus the detailed descriptions of the same elements will be omitted.
Referring to FIG. 6 , a transmissive type LCD apparatus 7000 includes a first member 200 , a alternative second member 5000 , a liquid crystal layer 400 interposed between the first and second members 200 and 5000 and a column spacer 430 b disposed between the first and second members 200 and 5000 so as to uniformly maintain a cell gap therebetween.
The alternative second member 5000 includes a gate electrode 110 , a first auxiliary electrode 140 , a gate insulating layer 170 , a semiconductor layer 320 , an ohmic contact layer 330 , a source electrode 210 , a drain electrode 310 operated as a second auxiliary electrode 313 , an organic layer 370 through which a contact hole 800 is formed so as to expose the second auxiliary electrode 313 , and a pixel electrode 410 formed on the second auxiliary electrode 313 exposed through the contact hole 800 and the organic layer 370 .
The pixel electrode 410 is electrically connected to the second auxiliary electrode 313 through the contact hole 800 and also electrically connected to the drain electrode 315 since the second auxiliary electrode 313 extends from the drain electrode 315 .
The column spacer 430 b is formed by depositing an organic layer (not shown) on a common electrode 240 formed on the first member 200 and patterning the organic layer.
The column spacer 430 b is formed in a non-effective display area where an auxiliary capacitor Cst makes contact with the pixel electrode 410 disposed on the organic layer 370 . Particularly, the column spacer 430 b makes contact with the pixel electrode 410 at an upper portion of the contact hole 800 formed on the organic layer 370 . The space in the contact hole 800 that is closed by the column spacer 430 b usually contains liquid crystals or air.
As described above, any reduction in the opening ratio of the transmissive type LCD apparatus 7000 due to the presence of the column spacer 430 b is avoided by forming the column spacer 430 b in the non-effective display area. Also, the column spacer 430 b prevents the first member 200 from being pushed down toward the alternative second member 5000 , for example when the transmissive type LCD apparatus 7000 is used as a touch screen device.
FIG. 7 is a cross-sectional view showing a transflective type LCD apparatus according to another exemplary embodiment of the present invention.
Referring to FIG. 7 , a transflective type LCD apparatus 8000 includes a alternative second member 5000 , a first member 200 and a liquid crystal layer 400 interposed between the lower and upper substrates 5000 and 200 .
The alternative second member 5000 includes a plurality of pixels arranged on an second substrate 100 in a matrix configuration. Each of the pixels includes a TFT 300 , a transmissive electrode 411 , a reflective electrode 412 , a first auxiliary electrode 140 , a second auxiliary electrode 313 and an organic layer 371 .
The TFT 300 having a gate electrode 110 , a source electrode 210 and a drain electrode 315 is formed on the second substrate 100 . Also, an auxiliary capacitor Cst having the first auxiliary electrode 140 , a gate insulating layer 170 and the second auxiliary electrode 313 is formed while the TFT 300 is formed.
The organic layer 371 is formed over the second substrate 100 on which the TFT 300 and auxiliary capacitor Cst are formed. The organic layer 371 has a contact hole 800 so as to expose the second auxiliary electrode 313 . Also, the organic layer 371 has an upper surface formed with concave and convex portions, thereby improving a reflectance of the reflective electrode 412 formed on the organic layer 371 .
The transmissive and reflective electrodes 411 and 412 are successively formed on the organic layer 371 . The transmissive and reflective electrodes 411 and 412 are electrically connected to the second auxiliary electrode 313 through the contact hole 800 . Also, the transmissive and reflective electrodes 411 and 412 may be electrically connected to the drain electrode 315 because the second auxiliary electrode 313 is an extension of the drain electrode 315 .
The first member 200 includes a black matrix layer 500 and a common electrode 240 . In the LCD device 10000 , the common electrode 240 is positioned on the surface of the first member 200 that is closest to the liquid crystal layer 400 . The liquid layer 400 is interposed between the common electrode 240 and the reflective or transmissive electrodes 412 and 411 . A first liquid crystal capacitor Clct is provided between the common electrode 240 and the transmissive electrode 411 and a second liquid crystal capacitor Clcr is provided between the common electrode 240 and the reflective electrode 412 .
A column spacer 430 a is disposed between the first and second members 200 and 5000 . A lower portion of the column spacer 430 a is received in the contact hole 800 , so that the column spacer 430 a makes contact with the reflective electrode 412 disposed on the second auxiliary electrode 313 .
As described above, any reduction in the opening ratio of the transmissive type LCD apparatus 8000 due to the formation of the column spacer 430 a is avoided by forming the column spacer 430 a in the non-effective display area where the auxiliary capacitor Cst is formed. Also, the column spacer 430 a prevents the first member 200 from being pushed down toward the alternative second member 5000 when the transmissive type LCD apparatus 8000 is used as a touch screen device.
In addition, the black matrix 500 formed on first member 200 is disposed on the non-effective display area corresponding to the column spacer 430 a . The black matrix prevents the column spacer 430 a from being projected onto a screen of the transflective type LCD apparatus 8000 , thereby improving the display quality of the transflective type LCD apparatus 8000 .
FIG. 8 is a cross-sectional view showing a transflective type LCD apparatus according to another exemplary embodiment of the present invention. In FIG. 8 , the same reference numerals denote the same elements in FIG. 7 , and thus the detailed descriptions of the same elements will be omitted.
Referring to FIG. 8 , a transflective type LCD apparatus 9000 includes a first member 200 , a alternative second member 5000 , a liquid crystal layer 400 interposed between the first and second members 200 and 5000 , and a column spacer 430 b disposed between the first and second members 200 and 5000 so as to uniformly maintain a cell gap between the substrates.
The alternative second member 5000 includes a gate electrode 110 , a first auxiliary electrode 140 , a gate insulating layer 170 , a semiconductor layer 320 , an ohmic contact layer 330 , a source electrode 210 , a drain electrode 310 operating as a second auxiliary electrode 313 , an organic layer 370 through which a contact hole 800 is formed so as to expose the second auxiliary electrode 313 , and a pixel electrode 410 formed on the second auxiliary electrode 313 exposed through the contact hole 800 and the organic layer 371 . The pixel electrode 410 includes a transmissive electrode 411 and a reflective electrode 412 formed on the transmissive electrode 411 .
The pixel electrode 410 is electrically connected to the second auxillary electrode 313 through the contact hole 800 and also electrically connected to the drain electrode 315 because the second auxiliary electrode 313 is an extension of the drain electrode 315 .
The column spacer 430 b is formed by depositing an organic layer (not shown) on a common electrode 240 formed on the first member 200 and patterning the organic layer.
The column spacer 430 b is formed on a non-effective display area where an auxiliary capacitor Cst contacts the pixel electrode 410 disposed on the organic layer 370 . Particularly, the column spacer 430 b makes contact with the reflective electrode 412 at an upper portion of the contact hole 800 formed on the organic layer 371 .
As described above, any reduction in the opening ratio of the transflective type LCD apparatus 9000 due to the presence of the column spacer 430 b is avoided by forming the column spacer 430 b in the non-effective area.
The first member 200 includes a black matrix layer 500 disposed on the non-effective display area near the column spacer 430 b . Due to the presence of the black matrix layer 500 , the column spacer 430 b is not projected onto a screen of the transflective type LCD apparatus 9000 , thereby improving the display quality of the transflective type LCD apparatus 9000 .
Also, the transflective type LCD apparatus 9000 may prevent the first member 200 from being pushed down toward the alternative second member 5000 because the column spacer 430 b is formed on the pixel electrode 410 .
FIG. 9 is a cross-sectional view showing a reflective LCD apparatus according to another exemplary embodiment of the present invention.
Referring to FIG. 9 , a reflective type LCD apparatus 10000 includes a alternative second member 5000 , a first member 200 and a liquid crystal layer 400 interposed between the lower and upper substrates 5000 and 200 .
The alternative second member 5000 includes a plurality of pixels arranged on an second substrate 100 in a matrix configuration. Each of the pixels includes a TFT 300 , a reflective electrode 416 , a first auxiliary electrode 140 , a second auxiliary electrode 313 and an organic layer 371 .
The TFT 300 having a gate electrode 110 , a source electrode 210 and a drain electrode 315 are formed on the second substrate 100 . Also, an auxiliary capacitor Cst having the first auxiliary electrode 140 , a gate insulating layer 170 and the second auxiliary electrode 313 are formed, e.g. when the TFT 300 is formed.
The organic layer 371 is formed over the second substrate 100 on which the TFT 300 and auxiliary capacitor Cst are formed. The organic layer 371 has a contact hole 800 so as to expose the second auxiliary electrode 313 . Also, the organic layer 371 has an upper surface formed with concave and convex portions, thereby improving a reflectance of the reflective electrode 416 formed on the organic layer 371 .
The reflective electrode 416 is formed on the organic layer 371 and electrically connected to the second auxiliary electrode 313 through the contact hole 800 . Also, the reflective electrode 416 may be electrically connected to the drain electrode 315 because the second auxiliary electrode 313 is an extension of the drain electrode 315 .
The first member 200 includes a black matrix layer 500 and a common electrode 240 . A column spacer 430 a is disposed between the first and second members 200 and 5000 . A lower portion of the column spacer 430 a is received in the contact hole 800 , so that the column spacer 430 a makes contact with the reflective electrode 416 disposed on the second auxiliary electrode 313 .
Thus, the reflective type LCD apparatus 10000 may prevent an opening ratio from being lowered due to the column spacer 430 a . Also, the reflective type LCD apparatus 10000 may prevent the first member 200 from being pushed down toward the alternative second member 5000 because the column spacer 430 a is formed on the reflective electrode 416 .
In addition, the black matrix 500 formed on the first member 200 is positioned to overlie the column spacer 430 a . Thus, the column spacer 430 a is not projected onto a screen of the reflective type LCD apparatus 10000 , thereby improving a display quality of the reflective type LCD apparatus 10000 .
FIG. 10 is a cross-sectional view showing a reflective type LCD apparatus according to another exemplary embodiment of the present invention. In FIG. 10 , the same reference numerals denote the same elements in FIG. 9 , and thus the detailed descriptions of the same elements will be omitted.
Referring to FIG. 10 , a reflective type LCD apparatus 11000 includes a first member 200 , a alternative second member 5000 , a liquid crystal layer 400 interposed between the first and second members 200 and 5000 and a column spacer 430 b disposed between the first and second members 200 and 5000 so as to uniformly maintain a cell gap therebetween.
The alternative second member 5000 includes a gate electrode 110 , a first auxiliary electrode 140 , a gate insulating layer 170 , a semiconductor layer 320 , an ohmic contact layer 330 , a source electrode 210 , a drain electrode 310 operated as a second auxiliary electrode 313 , an organic layer 371 through which a contact hole 800 is formed so as to expose the second auxiliary electrode 313 and a pixel electrode 416 formed on the second auxiliary electrode 313 exposed through the contact hole 800 and the organic layer 370 .
The pixel electrode 416 is electrically connected to the second auxiliary electrode 313 through the contact hole 800 and also electrically connected to the drain electrode 315 because the second auxiliary electrode 313 is an extension of the drain electrode 315 .
The column spacer 430 b is formed by depositing an organic layer (not shown) on a common electrode 240 formed on the first member 200 and patterning the organic layer.
The column spacer 430 b is formed on a non-effective display area where an auxiliary capacitor Cst having the first and second auxiliary electrodes 140 and 313 makes contact with the pixel electrode 416 disposed on the organic layer 371 .
As described above, the column spacer 430 b is formed on the non-effective display area to prevent any reduction of the opening ratio in the reflective type LCD apparatus 11000 .
The first member 200 includes a black matrix layer 500 disposed on the non-effective display area overlying the column spacer 430 b . The black matrix layer 500 prevents the column spacer 430 b from being projected onto a screen of the reflective type LCD apparatus 11000 , thereby improving a display quality of the reflective type LCD apparatus 11000 .
Also, the reflective type LCD apparatus 11000 may prevent the first member 200 from being pushed down toward the alternative second member 5000 because the column spacer 430 b is formed on the pixel electrode 416 .
FIG. 11 is a cross-sectional view showing an LCD apparatus having a plurality of column spacers according to an exemplary embodiment of the present invention.
Referring to FIG. 11 , an LCD apparatus 600 includes a first member 200 , a second member 1000 combined with the first member 200 , a sealant 700 disposed between the upper and lower substrate 200 and 1000 to hold the first and second members 200 and 1000 together, and a plurality of column spacer 430 disposed between the first and second members 200 and 1000 to uniformly maintain a cell gap between the substrates.
The LCD apparatus 600 is divided into a display area DA where a plurality of pixels are formed and a peripheral area PA surrounding the display area DA.
The sealant 700 is formed between the first and second members 200 and 1000 in the peripheral area PA. The column spacers 430 are disposed between the first and second members 200 and 1000 in the display area DA. A plurality of layers other than the spacers, such as an insulating layer, an electrode layer or the like, are formed in the display area DA. The column spacers 430 are also formed on the layers. Since the plurality of layers are formed in the display area but not in the peripheral area, each of the column spacers 430 has a length smaller than a length of the sealant 700 .
As shown in FIG. 11 , the distance between the column spacers 430 is not constant. In the example shown, the distance between two immediately neighboring spacers 430 decreases as the center of the second member 1000 is approached. Thus, generally, the spacers 430 are positioned closer together farther away from the peripheral area PA. The reason for this arrangement is that the column spacers 430 disposed in an area of the display area DA near the peripheral area PA receive “help” from the sealant 700 in absorbing an impact applied to an outer portion of the display area DA. When the contribution from the sealant 700 is taken into account, fewer column spacers 430 are needed to absorb the same strength of force. Thus, the column spacers 430 near the peripheral area PA can be sparsely arranged. In contrast, the column spacers 430 near the center portion of the display area DA do not receive much “help” from the sealant 700 , and have to absorb the impact by themselves. Thus, more column spacers 430 are needed to absorb the same strength of force near the center portion of the substrate, calling for a denser arrangement of the spacers 430 .
FIGS. 12A to 12F illustrate a method of manufacturing an LCD apparatus according to an exemplary embodiment of the present invention.
Referring to FIG. 12A , a metal layer, such as aluminum or aluminum alloy, is deposited on an second substrate 100 and patterned through a first mask process to form a first auxiliary electrode 140 . The first auxiliary electrode 140 is formed separately from a gate line or a data line described below.
Referring to FIG. 12B , a metal layer containing chromium (Cr), molybdenum (Mo), tantalum (Ta) or antimony (Sb) is deposited on the second substrate 100 and patterned through a second mask process to form a gate electrode 110 and a gate line (not shown).
Referring to FIG. 12C , a gate insulating layer 170 containing an inorganic material is formed over the second substrate 100 on which the gate electrode 110 and first auxiliary electrode 140 are formed. Then, an intrinsic semiconductor, such as amorphous silicon, and an extrinsic semiconductor doped with impurities are successively deposited on the gate insulating layer 170 . The extrinsic and intrinsic semiconductors are sequentially patterned through a third mask process to form an ohmic contact layer 330 and a semiconductor layer 320 .
Referring to FIG. 12D , a metal layer containing chromium is formed over the second substrate 100 and patterned through a fourth mask process to form a source electrode 210 , a drain electrode 315 , a second auxiliary electrode 313 and a data line (not shown).
The source electrode 210 is overlapped with an end of the gate electrode 110 and the drain electrode 315 is overlapped with another end of the gate electrode 110 , thereby forming a TFT 3000 on the second substrate 100 .
The second auxiliary electrode 313 is an extension of the drain electrode 315 so as to be overlapped with the first auxiliary electrode 140 . The first auxiliary electrode 140 , second auxiliary electrode 313 and gate insulating layer formed between the first and second auxiliary electrodes 140 and 313 are operated as an auxiliary capacitor Cst.
Referring to FIG. 12E , an organic layer 370 containing an organic insulating material, such as poly-benzocyclobutene, is formed over the second substrate 100 on which the TFT 300 and auxiliary capacitor Cst are formed. The organic layer 370 is patterned through a fifth mask process to form a contact hole 800 , which partially exposes the second auxiliary electrode 313 .
Referring to FIG. 12F , an ITO is deposited on the organic layer 370 and patterned through a sixth mask process to form a pixel electrode 410 . The pixel electrode 410 is electrically connected to the second auxiliary electrode 313 through the contact hole 800 .
As shown in FIG. 5 , a column spacer 430 a is formed overlying the auxiliary capacitor Cst. That is, a lower portion of the column spacer 430 a is received in the contact hole 800 so that the column spacer 430 a makes contact with the pixel electrode 410 disposed on the second auxiliary electrode 313 .
The column spacer 430 b may make contact with the pixel electrode 410 at an upper portion of the contact hole 800 so as to be supported by the pixel electrode 410 as shown in FIG. 6 .
As described above, when the column spacers 430 a and 430 b are formed on a non-effective display area on which the auxiliary capacitor Cst is formed, the LCD apparatus shown in FIGS. 12A to 12F may prevent an opening ratio from being lowered due to the column spacers 430 a and 430 b.
Also, the LCD apparatus shown in FIG. 12A to 12F may prevent the first member 200 (see FIG. 5 or 6 ) from being pushed down or bending toward the lower substrate 100 because the column spacers 430 a and 430 b are formed on the pixel electrode 410 .
Although the exemplary embodiments of the present invention have been described, it is understood that the present invention should not be limited to these exemplary embodiments but various changes and modifications can be made by one ordinary skilled in the art within the spirit and scope of the present invention as hereinafter claimed. | The invention includes a liquid crystal display panel including spacers and a method of making this panel. The spacers, which are positioned in the liquid crystal-filled gap between a first substrate and a second substrate, provide support to the substrates and prevent the substrate from bending when the device is used as a touch screen panel. By preventing the bending of the device, the spacers help prevent the undesirable ripple effect suffered by liquid crystal devices. In order to minimize the amount of light blocked by the spacers, the spacers are formed in a region where light is substantially intercepted anyway, such as in a contact hole. A black matrix layer is formed on the spacers. The spacers may be distributed unevenly between the substrates, depending on how much force each of the spacers will have to absorb in each area of the panel. | 6 |
TECHNICAL FIELD OF THE INVENTION
This invention relates, in general, to a connector for tapping into a pipe and, in particular, to a self-locking, leak resistant connector for attaching a downhole tool to the pipe.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with downhole pressure sensing, as an example.
In the process of drilling, testing, completing or producing an oil and gas well, it is often useful to be able to measure the pressure at various locations of the well. For example, of particular interest is the pressure in the various production zones that are traversed by the well. Typically, this may be achieved by including a pressure transducer as a portion of a test string included in the pipe string.
Alternatively, attempts have been made to place a pressure transducer on the outside diameter of the tubing or pipe string. Attaching the pressure transducer to the outside of the pipe string typically utilizes a threaded engagement usually included some form of tapered pipe thread, such as a National Pipe Threads (NPT). Although these types of threads are often used in such applications, it has been found that the pressure differential across the threads in testing or other well operations often exceed the specified pressure rating of the threads which has resulted in inaccurate pressure readings due to leakage. Additionally, it has been found that using threaded connections often makes installation of the pressure transducer on the outside of the pipe string difficult.
A need has, therefore, arisen for an apparatus for obtaining downhole pressure readings from the outside of a pipe string that does not rely on a metal to metal seal to prevent leakage. A need has also arisen for such an apparatus that is simple and quick to install. Further, a need has arisen for such an apparatus that may obtain pressure reading from both inside and outside of the pipe string and that may be locked in place following installation in order to withstand the hostile downhole environment.
SUMMARY OF THE INVENTION
The present invention disclosed herein comprises an apparatus and method for connecting a downhole tool to the outside of a pipe string that does not rely on a metal to metal seal to prevent leakage. The apparatus is simple and quick to install and may provide a path for fluid communication from both inside and outside of the pipe string to obtain pressure, temperature or fluid composition data and the like. The apparatus is self-locking with the pipe string and is thereby able to withstand the hostile downhole environment.
The present invention comprises a connector that includes a connector head and a first coupling extending from the connector head in a first direction. The connector also includes a second coupling extending from the connector head in a second direction perpendicular to the first direction that receives a downhole tool thereon. The connector head has a first dimension corresponding to the length of the connector head parallel to the axis of the second coupling. The connector head has a second dimension corresponding to the length of the connector head perpendicular to the axis of the first coupling and perpendicular to the axis of the second coupling. The length of the first dimension is larger than the length of the second dimension such that the connector is self-locking within a pipe section of the present invention. The pipe section of the present invention has a longitudinal slot with first and second sides. A transverse slot extends perpendicularly from the first side of the longitudinal slot and a hole extending perpendicularly from the second side of the longitudinal slot.
The first coupling of the connector is insertable into the hole such that the connector may be rotated between an insertion position and an operating position. Once the first coupling is fully inserted into the hole and the connector head is aligned with the longitudinal slot of the pipe section, the connector may be rotated from the insertion position to the operating position. The connector head is closely received within the longitudinal slot such that when the connector is in the operating position, the connector head contacts the first side of the longitudinal slot, thereby locking the first coupling within the hole and locking the connector within the pipe section.
The first coupling of the connector may include a flange and a radially reduced area. An annular seal may be disposed about the radially reduced area to provide a seal between the first coupling and the hole. Similarly, the second coupling of the connector may include a flange and a pair of radially reduced areas having a separator flange therebetween. A pair of annular seals may be disposed respectively about the pair of radially reduced areas to provide a seal between the second coupling and the pressure transducer.
In one embodiment of the present invention, the pipe section includes a port that provides fluid communication between the hole and the interior of the pipe section and the connector includes a fluid passageway that provides fluid communication through the first coupling, the connector head and the second coupling. In this embodiment, a pressure transducer attached to the second coupling may obtain pressure readings from the interior of the pipe section.
In another embodiment of the present invention, the connector includes a fluid passageway extending through a portion of the second coupling and at least one port providing fluid communication between the fluid passageway and the outside of the second coupling. In this embodiment, a pressure transducer attached to the second coupling may obtain pressure readings from the exterior of the pipe section.
In the method of the present invention, the connector has a downhole tool coupled thereto and is received within the pipe section such that the connector head may slide within the transverse slot of the pipe section. The first coupling is then inserted into the hole of the pipe section and the connector is rotated between the insertion position and the operating position such that connector head is closely received within the longitudinal slot. Upon rotation, the connector is locked in place within the pipe section. The pipe section, including the connector and the downhole tool is then disposed downhole.
BRIEF DESCRIPTION OF THE DRAWINGS
For a complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention taken in conjunction with the accompanying drawings in which like numerals identify like parts and in which:
FIG. 1 is a schematic illustration of an offshore oil and gas platform operating a connector of the present invention;
FIG. 2 is an enlarged view of a connector of the present invention attached to a pipe section;
FIGS. 3A-3C are respectively side, front and top elevation views of a connector of the present invention;
FIG. 4 is a perspective view of a connector of the present invention being locked onto a pipe section; and
FIGS. 5A-5C are respectively side, front and top elevation views of another connector of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
Referring to FIG. 1, a connector in use during an offshore testing operation is schematically illustrated and generally designated 10. Semisubmersible platform 12 is centered over a submerged oil and gas formation 14 located below sea floor 16. Subsea conduit 18 extends from deck 20 of platform 12 to a wellhead installation 22 including blowout preventors 24. Platform 12 has hoisting apparatus 26 and a derrick 28 for raising and lowering pipe string 30 including pipe section 32 that receives connector 34 and pressure transducer 36. Using pipe section 32, connector 34 and pressure transducer 36, pressure reading may be obtained from within pipe string 30. Alternatively, if seal assembly 38 is operated to seal between pipe string 30 and wellbore 40, pressure reading may be obtained from either within pipe string 30 or from the annulus between pipe string 30 and wellbore 40 depending upon the configuration of connector 34.
Even though pipe section 32, connector 34 and pressure transducer 36 have been depicted during a well testing operation, it should be understood by one skilled in the art that pipe section 32 and connector 34 of the present invention in conjunction with pressure transducer 36 are equally well-suited for use during all phases of the life of wellbore 40 including, but not limited to, drilling, completing and producing the well.
Even though connector 34 has been use to connect pressure transducer 36 to pipe section 32, it should be understood by one skilled in the art that a variety of other tools may be connected to pipe section 32 by connector 34. For example, tools such as a temperature transducer, a fluid sampling device and the like may alternatively be attached to pipe section 32 by connector 34 of the present invention.
Referring to FIG. 2, an enlarged view of pipe section 32 is depicted. Pipe section 32 includes a wide longitudinal slot 60 and a narrow longitudinal slot 62 having sides 78, 80. Extending perpendicularly from side 78 of narrow longitudinal slot 62 is a transverse slot 64. Extending perpendicularly from side 80 of narrow longitudinal slot 62 is a hole 66. This combination of slots 60, 62, 64 and hole 66 receives and retains connector 34 and pressure transducer 36.
Narrow longitudinal slot 62 has a dimension, a, that represents the width of narrow longitudinal slot 62. As will be more fully discussed below, narrow longitudinal slot 62 closely receives connector 34 between sides 78, 80 to prevent relative transverse movement between pipe section 32 and connector 34 once connector 34 is installed. Transverse slot 64 has a dimension, b, that represents the width of transverse slot 64. In conjunction with narrow longitudinal slot 62, transverse slot 64 prevents relative transverse movement between connector 34 and pipe section 32, as will be more fully discussed below.
Connector 34 includes a pair of radially reduced areas 68 around which annular seals 70 may be placed. Annular seals 70 create a sealing engagement between connector 34 and pressure transducer 36 such that accurate pressure readings may be obtained. Connector 34 also has a radially reduced area 72 around which an annular seal 70 is placed such that a sealing engagement is created between connector 34 and hole 66.
Pipe section 32 includes a port 74 that provides a path for fluid communication between the interior of pipe section 32 and hole 66. Fluid passageway 76 of connector 34 provides a path for fluid communication through connector 34 between hole 66 and pressure transducer 36. Pressure readings from inside pipe section 32 are thereby obtained utilizing port 74 and fluid passageway 76 to transmit fluid pressure between the interior of pipe section 72 and pressure transducer 36.
Even though FIG. 2 has depicted connector 34 in a vertical orientation, it should be noted by those of ordinary skill in the art that connector 34 may be oriented in any position. For example, connector 34 is equally well-suited for use in a deviated or horizontal well.
Referring now to FIGS. 3A-3C, connector 34 is depicted in side, front and top elevation views. Connector 34 has a connector head 100. Extending outwardly from connector head 100 is pipe coupling 102. Pipe coupling 102 has an outer flange 104 and a radially reduced area 72 for receiving and retaining an annular seal 70 such that when connector 34 is coupled with pipe section 32, as depicted in FIG. 2, a sealing engagement is created between pipe coupling 102 and hole 66 of pipe section 32. Extending outwardly from connector head 100 at a ninety degree angle from pipe coupling 102 is transducer coupling 106. Transducer coupling 106 has an outer flange 108, a separator flange 110 and a pair of radially reduced areas 68. Radially reduced areas 68 receive and retain annular seals 70. Separator flange 110 maintains a spaced apart relationship between the annular seals 70. Annular seals 70 create a sealing engagement between transducer coupling 106 and pressure transducer 36.
Connector 34 has fluid passageway 76 that extends between pipe coupling 102 and transducer coupling 106 through connector head 100. Fluid passageway 76 allows fluid communication between pipe coupling 102 and transducer coupling 106 thereby allowing pressure reading from the interior of pipe section 32 to be obtained by pressure transducer 36, as depicted in FIG. 2.
Connector head 100 of connector 34 is a rectangular prism having dimensions c, d and e. Dimension, c, represents the length of connector head 100 extending coaxially from transducer coupling 106 and perpendicular to the axis of pipe coupling 102. Dimension, d, represents the length of connector head 100 extending coaxially from pipe coupling 102 and perpendicular to the axis of transducer coupling 106. Dimension, e, represents the length of connector head 100 extending perpendicular to transducer coupling 106 and perpendicular to pipe coupling 102.
Even though connector head 100 has been described as a rectangular prism, it should be understood by one skilled in the art that connector head 100 may be designed using other geometric shapes so long as the relative dimension characteristics of connected head 100 with respect to pipe section 32 are maintained. For example, connector head 100 may be designed having a cylindrical shape.
Referring to FIG. 4 and with reference to FIGS. 2 and 3A-3C, the installation procedure for connector 34 to pipe section 32 is depicted. Pressure transducer 36 is fitted over transducer coupling 106 of connector 34. Pressure transducer 36 may be any suitable pressure transducer that is well known in the art which can be mounted within wide longitudinal slot 60. To attach connector 34 to pipe section 32, pipe coupling 102 is coaxially aligned with hole 66 of pipe section 32, as best seen in FIG. 2. Connector 34 may then be rotated so that transducer coupling 106 is perpendicular to pipe section 32, as best seen in FIG. 4. Connector head 100 of connector 34 may then slide toward hole 66 through transverse slot 64. Width, b, of transverse slot 64 is greater than length, e, of connector head 100, allowing connector head 100 to be received therein and slide therethrough. Pipe coupling 102 is inserted into hole 66 of pipe section 32 until connector head 100 is aligned with narrow longitudinal slot 62 between sides 78, 80, as best seen in FIG. 2. In order to lock connector 34 in place, hydraulic connector 34 is rotated around the axis of pipe coupling 102. As connector 34 is rotated about the axis of pipe coupling 102, connector head 100 rotates within narrow longitudinal slot 62. The width, a, of longitudinal slot 62 is greater than length, d, of connector head 100 and is sized to closely receive connector head 100. Once connector 34 is rotated ninety degrees, connector 34 is locked within pipe section 32 between sides 78, 80 of narrow longitudinal slot 62. The fact that length, c, of connector head 100 is longer than width, b, of transverse slot 64 prevents pipe coupling 102 from sliding out of hole 66 and prevents connector 34 from sliding out of pipe section 32 once connector 34 is locked in place. Once connector 36 is locked in place, pressure reading from the interior of pipe section 32 may be obtained by pressure transducer 36 through port 74 and fluid passageway 76.
Now referring to FIGS. 5A-5C, another embodiment of connector 234 is depicted. Connector 234 has a connector head 200. Extending outwardly from connector head 200 is pipe coupling 202. Pipe coupling 202 has an outer flange 204 and a radially reduced area 272 for receiving and retaining an annular seal 270 such that when connector 234 is coupled with pipe section 32, as depicted in FIG. 2, a sealing engagement is created between pipe coupling 202 and hole 66 of pipe section 32. Extending outwardly from connector head 200 at a ninety degree angle from pipe coupling 202 is transducer coupling 206. Transducer coupling 206 has an outer flange 208, a separator flange 210 and a pair of radially reduced areas 268. Radially reduced areas 268 receive and retain annular seals 270. Separator flange 210 maintains a spaced apart relationship between the annular seals 270. Annular seals 270 create a sealing engagement between transducer coupling 206 and pressure transducer 36.
Connector 234 has fluid passageway 276 that extends through a portion of transducer coupling 206. Connector 234 also has a pair of ports 278, 280, that provide for fluid communication between the outside of connector 234 and fluid passage 276. Fluid passageway 276 allows fluid communication between ports 278, 280 and pressure transducer 36 thereby allowing pressure reading from the exterior of pipe section 232 to be obtained by pressure transducer 36.
Connector head 200 of connector 234 is a rectangular prism having dimensions c, d and e. Dimension, c, represents the length of connector head 200 extending coaxially from transducer coupling 206 and perpendicular to the axis of pipe coupling 202. Dimension, d, represents the length of connector head 200 extending coaxially from pipe coupling 202 and perpendicular to the axis of transducer coupling 206. Dimension, e, represents the length of connector head 200 extending perpendicular to transducer coupling 206 and perpendicular to pipe coupling 202. Connector 234 may be installed within pipe section 32 in the manner described above with reference to connector 34 in FIG. 4.
While this invention has been described with a reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. | An apparatus and method for sampling downhole fluids comprising a tool (36) attached to a connector (34) that is locked into position within a pipe section (32) is disclosed. The pipe section (32) has a longitudinal slot (62) with first and second sides (78, 80). The pipe section (32) also includes a transverse slot (64) that extends perpendicularly from the first side (78) of the longitudinal slot (62) and a hole (66) that extends perpendicularly from the second side (80) of the longitudinal slot (62). The connector (34) is inserted into the hole (66) such that the connector (34) may be rotated between an insertion position and an operating position. The connector head (100) of the connector (34) is closely received within the longitudinal slot (62) such that when the connector (34) is in the operating position, the connector head (100) contacts the first side (78) of the longitudinal slot (62) to lock the connector (34) within the pipe section (32). | 4 |
This application is a continuation of application Ser. No. 913,288, filed Sept. 30,1986, now abandoned.
FIELD OF THE INVENTION
This invention relates to business communication systems and, in particular, to an adjunct processor which provides computer facility access protection by way of the call transfer feature of the business communication system.
PROBLEM
It is a problem in dial-up type computer systems to prevent the unauthorized access of computer facilities. A common method of providing relatively secure access protection for a computer system is to equip each computer port with a callback unit. A callback unit is a device connected between a telephone line and a computer port to limit access to the computer to only those users having the proper authorization. A calling party dials the access number of the computer port and is connected by the business communication system to the callback unit. The callback unit prompts the calling party to provide the proper password and user identification information which is used by the callback unit to validate the identity of the calling party as an authorized user of the computer facility. The callback unit reviews a list of authorized users stored in the callback unit memory to determine whether the password sequence entered by the calling party matches the list of authorized users. If a match occurs, the callback unit reads the telephone number associated with the calling party from the list. The callback unit then disconnects the calling party from the computer port and initiates an outgoing call from the computer port to the calling party at the predesignated telephone number. The calling party responds to this call from the callback unit by going off hook on the telephone station set or computer terminal and is cut through by the callback unit to the computer port. The callback unit remains connected in series between the calling party and the computer port for the duration of the call.
The problem with this arrangement is that every computer port must be equipped with a callback unit in order to obtain the required level of security. These callback units are relatively expensive and the cost to the customer to protect a computer center which serves numerous computer ports is prohibitive. More sophisticated personnel identification equipment, such as voiceprint identifiers, would provide a significantly improved level of security for the computer system, but to equip each callback unit with such equipment renders the cost of security beyond the reach of almost every computer system manager. Solution
This problem is overcome and a technical advance achieved by the subject adjunct processor that provides computer facility access protection via the data call transfer capability of the business communication system. This adjunct processor arrangement performs a centralized call screening function to provide computer facility access security. Every call origination in the business communication system from a user to a protected computer facility is interdicted by the business communication system and routed to the adjunct processor. The user receives a series of prompts from the adjunct processor to provide identification information, such as login, password, and voiceprint information. The adjunct processor validates the identity of the user using this identification indicia and initiates a callback operation. The adjunct processor disconnects the user from the call connection, calls the user back and then uses the data call transfer capability of the business communication system to connect the user to the computer facility. The adjunct processor releases from the call connection and is available to screen another calling party. In this fashion, extensive and expensive security facilities, such as voiceprint identification apparatus, can be provided in the centralized adjunct processor to give the users a very high level of security since the cost of these security facilities is distributed over all of telephone switching system users.
In a large business communication system, there can be numerous computer facilities served by the business communication system. These computer facilities can be mainframe computers, each of which is equipped with a plurality of access ports, or personal computers, each of which is connected to an individual user's telephone line in conjunction with the user's telephone station set. In the case of the personal computers, the cost of security quickly becomes prohibitive due to the large number of computer facilities in contrast with large mainframe computers each served by only a small number of access ports.
The adjunct processor security arrangement of the present invention provides a centralized call screening function. The calling party dials either the adjunct processor or the access number of a computer port. In the former case, the calling party is directly connected through the switching network to the adjunct processor. In the latter case, the switch processor of the business communication system recognizes, for example through the class of service associated with this dialed number, that the destination identified by the dialed number is a protected computer facility. The switch processor ignores the number dialed by the calling party and connects the calling party directly through the switching network to the adjunct processor. The switch processor transmits control messages to the adjunct processor identifying the calling party, the dialed number as well as any other relevant information about the protected computer facility.
The adjunct processor provides a series of standardized prompts to the calling party to elicit password and calling party identification information. This information can be as simple as a multiple character password typed on a computer terminal keyboard or can be as sophisticated as a voiceprint obtained from the calling party over the communication connection. The calling party identification information is used by the adjunct processor to validate the identity of the calling party.
Once the calling party has been identified, the adjunct processor scans a list of authorized users stored in an adjunct processor memory to retrieve from memory a predesignated telephone number assigned to this calling party. The adjunct processor disconnects the calling party from the call connection and initiates a new data call connection from the adjunct processor to the predesignated number associated with the calling party. The business communication system completes this data call connection to the calling party from the adjunct processor. The adjunct processor, in response to the completion of a data call connection, initiates a standard data call transfer operation. The adjunct processor signals the switch processor to indicate the identity of the protected computer facility to which the calling party is requesting access as well as the port on the adjunct processor to which the calling party is presently connected. The switch processor disconnects the calling party from the adjunct processor and establishes a new switching network connection from the calling party to one of the port circuits associated with the protected computer facility designated by the number originally dialed by the calling party.
If the calling party is not at a predesignated location, the callback operation can be dispensed with and a simple data call transfer operation used to connect the calling party to the protected computer facility. This is useful in the case where the calling party accesses the protected computer facility from a remote location or from a location other than the predesignated location assigned to the calling party. The callback operation can also be dispensed with if the user identity validation is relatively foolproof, such as in the case of a voiceprint identification.
This centralized adjunct processor calling party screening apparatus provides a cost effective method to achieve a high level of security for all of the computer ports served by the business communication system. The data call transfer capability of the business communication system enables the adjunct processor to be disconnected from the call connection upon completion of the call screening operation. The adjunct processor can thereby serve a plurality of computer ports.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention may be better understood from a reading of the following description of one possible exemplary embodiment taken in conjunction with the drawing in which:
FIG. 1 illustrates, in block diagram form, the structure of both the subject adjunct processor for providing computer facility access protection and the associated business communication system; and
FIG. 2 illustrates, in flow diagram form, the method of operation of the subject adjunct processor for providing computer facility access protection.
DETAILED DESCRIPTION
FIG. 1 illustrates, in block diagram form, the adjunct processor for providing computer facility access protection as well as a business communication system in which it operates. The business communication system can be any one of a number of digital switching systems and, for the purpose of this description, is assumed to be an AT&T System 85 switch. FIG. 1 illustrates a plurality of terminal equipment T100-Tn each of which is associated with a respective one of the business communication system port circuits L100-Ln. This terminal equipment includes telephone station sets as well as digital terminal devices. The business communication system is also equipped with a plurality of trunk circuits 150-151 which interconnect the business communication system with the local telephone company central switching equipment. A number of computer facilities are also connected to the business communication system. These computer facilities include one or more general purpose computers (computer A, computer B) each of which is connected via a plurality of associated computer ports 130-13n, 140-14n to the business communication system. The business communication system includes a switching network 102, connected via communication leads C100-Cn to the port circuits L100-Ln, via communication leads C130C13m, C140-C14m to computer ports 130-13m, 140-14m, and via communications leads C150-151 to trunk circuits 150-151. Switch processor 101 is connected to all of the port circuits by bus 105, which functions to carry control signs between switch processor 101 and the port circuits (120-151, L100-Ln). Switching network 102 functions under the control of switch processor 101 to establish communication connections among the communication devices comprising the terminal equipment, trunk circuits and computers by interconnecting the associated port circuits. This business communication system is also equipped with modem devices (e.g., 161) associated with a trunk data module 160 which functions to convert the analog signals received from one of trunk circuits 150- 151 to digital signals for use by one of the computer facilities 113-114.
ADJUNCT PROCESSOR
In addition to the above mentioned terminal equipment and computer facilities, the business communication system illustrated in FIG. 1 is connected to adjunct processor 104 to provide computer facility access protection. In this exemplary embodiment, adjunct processor 104 comprises security computer 112 connected to switching network 102 via a number of security devices 12012m and their associated communication leads C120-C12m. Adjunct processor 104 can comprise any of a number of device configurations as dictated by the need to provide a defined level of computer facility access security. For example, the desired level of security can require a simple login/password access. Alternatively, the desired level of security can be more stringent and require user identification via validation of some immutable physical characteristic of the user. Examples of such physical characteristic identification apparatus includes: fingerprint reader devices such as that manufactured by Identix Corp.; voiceprint identification algorithms; retina scan apparatus. The cost of such physical characteristic identification apparatus is high and, for the purpose of this description, it will be assumed that a combined login/password and voiceprint identification arrangement is provided in adjunct processor 104.
Assume for the purpose of this description that adjunct processor 104 is implemented by means of a security computer 112 connected via a plurality of security devices 120-12m and their associated communication leads C120-12m to switching network 102. Security computer 112 can be a personal computer such as the AT&T UNIX™ PC which is equipped with voiceprint matching software. In addition, security computer 112 is equipped with a number of security devices 120-12m such as the AT&T DCPI card which, in this case, provides a simple digital interface between security computer 112 and switching network 102 via communication leads C120-12m and between security computer 112 and switch processor 101 via bus 105. Security devices 120-12m appear to switch processor 101 as port circuits serving a digital telephone station set. Security computer 112 has stored in memory, for example, a list of authorized computer users, the user's login/password identifiers, a sample of the user's voiceprint and a predetermined telephone number associated with the user's terminal device.
CALL SCREENING
Adjunct processor 104 functions to screen incoming calls to all the computer facilities served by the business communication system. This is accomplished in one of two ways. A calling party can directly call adjunct processor 104 via switching network 102 and one of security devices 120-12m. Alternatively, switch processor 101 interdicts each call originated by a calling party at a communication device (e.g., T100) to a protected computer facility (e.g., computer A). Switch processor 101 activates switching network 102 via signal path 103 to connect the calling party at communication device T100 to one of security devices 120-12m associated with adjunct processor 104.
Security computer 112, in conjunction with the security device (e.g., 120) connected to the calling party at communication device T100, determines the identity of the calling party by means of an exchange of password/login and voiceprint information. Security computer 112 uses this information to determine, from a list of preassigned telephone numbers, the location of the calling party at communication device T100. Security computer 112 through security device 120 disconnects communication device T100 from the call connection and initiates a return data call to the calling party using the preassigned telephone number from the list stored in security computer 112. Security computer 112 completes this call connection via associated security device 120 to communication device T100 associated with the calling party and then initiates a data call transfer operation to connect the calling party to the designated protected computer facility (computer A). The data call transfer operation is accomplished by security device 120 signaling switch processor 101 over bus 105 using standard telephone station set data call transfer button push signals. If the calling party is not at a preassigned telephone number, yet is permitted access to a protected computer facility, an alternative method of operation is to bypass the callback operation and simply transfer the call to the protected computer facility.
CALL CONNECTION OPERATION
In order to more fully understand the operation of adjunct processor 104 in providing computer facility access security, a simple call connection operation will be described. FIG. 2 illustrates, in flow diagram form, the steps required to interconnect a calling party to a protected computer facility. Assume for the purpose of this discussion, that a calling party at telephone station set T1OO goes off hook and dials the telephone number associated with computer A (step 201). The digits dialed by the calling party at telephone station set T100 are carried via port circuit L100 to switch processor 101 via bus 105. Switch processor 101, in response to the dialed digits, identifies (step 202) the called number as one of the protected computer ports 130-13n associated with computer A. The identification operation can be as simple as recognizing a unique class of service assigned to a protected computer port. Switch processor 101 responds to a calling party attempt to access a protected computer port by activating switching network 102 to connect (step 203) the calling party (telephone station set T1OO) to one of security devices (e.g., 120) associated with security computer 112. (Alternatively, the calling party can directly dial (step 200) the access number of adjunct processor 104). Security device 120 signals (step 204) security computer 112 that a calling party is connected via switching network 102 to security device 120. In addition, switch processor 101 transmits (step 204) control messages in the form of ISDN messages or digital telephone station set display messages over bus 105 to security computer 112 to identify the calling party and the protected computer port, via security device 120 to which the calling party T100 is now connected.
LOGIN/PASSWORD PROMPTS
Security computer 112 now performs the calling party screening function. Security computer 112, via security device 120, transmits (step 205) a prerecorded prompt message to the calling party at telephone station set T100 connected via switching network 102 to security device 120. Security device 120, in well known fashion, cues the calling party at telephone station set T100 to enter (step 206) preliminary login/password identification information to uniquely identify the calling party. In addition, security device may prompt the calling party to enter the telephone number of the computer to which the calling party is requesting access. This step is necessary in the case where the calling party directly dials adjunct processor 104. Security device 120 forwards (step 207) this identification indicia to security computer 112 for further processing. Security computer 112 contains in its memory a list of all authorized calling parties, their associated logins/passwords, telephone numbers and voiceprints. These telephone numbers can either be on premise extension numbers such as telephone station set T100 or these telephone numbers can be off premise direct dial numbers in the case where a calling party accesses a computer facility by way of one of trunk circuits 150-151. In either case, security computer 112 scans (step 208) the list of authorized users using the identification indicia obtained from the calling party by security device 120.
In the case where no match occurs between the retrieved identification information and the list stored on security computer 112, security computer 112 signals (step 211) security device 120 to disconnect the calling party's telephone station set T100 from the call connection and to terminate call processing. In the case where there is a match between the identification of the calling party and the list stored in the memory of security computer 112, security computer 112 returns to step 205.
VOICEPRINT PROMPT
Security computer activates (step 205) security device 120 to provide a prerecorded prompt message to the calling party at telephone station set T1OO. The calling party provides (step 206) a predefined voice response to match the stored voiceprint. Security device 120 transmits the received voice response to security computer 112 which compares the stored voiceprint with the response of the calling party to determine the quality of the measured match. Security computer 112 signals (step 211) security device 120 to terminate the call if no match occurs.
CALLBACK AND TRANSFER
If a match does occur, security computer 112 causes security device 120 to disconnect (step 209) the calling party's telephone station set T100 from the call connection and to immediately initiate an outgoing data call from security device 120 to the predetermined telephone number associated with the calling party as retrieved from the list stored in security computer 112. In the case presently under consideration, security device 120 dials the telephone number of the calling party at telephone station set T100. Switch processor 101 responds to the dialing of security device 120 and establishes a data call connection through switching network 102 from security device 120 via port circuit L100 to telephone station set T100. Upon completion of this call connection, security computer 112 initiates (step 210) a data call transfer operation to transfer the data call connection of calling party at telephone station set T100 from security device 120 to one of the protected computer ports 130-13m associated with computer A. Alternatively, if the calling party is not at a preassigned telephone number, security computer 112 can bypass the callback operation (step 209). This is accomplished by security computer 112 transmitting ISDN control messages or data call transfer button push signals to switch processor 101 via security device 120 and scan bus 105 to indicate a request for a data call transfer operation. Switch processor 101 responds to these control messages by enabling switching network 102 to disconnect the calling party call connection from telephone station set T1OO and port circuit L100 to security device 120 and to establish a new data call connection through switching network 102 from port circuit L100 to one of the protected computer ports (e.g., 130) associated with computer A. In this fashion, the calling party at telephone station set T100 is now connected via port circuit L100 and switching network 102 to computer port 130 associated with computer A.
TRUNK CALL
The above description illustrates the method of operation of adjunct processor 104 in providing computer port access protection. The above description is illustrative of the philosophy of this invention and it is obvious that the calling party can access a protected computer port either from one of telephone station sets T100-Tn or from a remote location over any one of trunk circuits 150-151. It is also obvious that although mainframe computers such as computer A and computer B each having a plurality of computer ports, were illustrated in FIG. 1, the operation of adjunct processor 104 also applies to the case where the computer port to be protected is a personal computer associated with the telephone station set and connected to switching network 102 via a port circuit.
It is important to note that in the case of user access via a trunk circuit, there can be the need for a modem interconnection. If the incoming trunk circuit (e.g., 150) is an analog trunk, switch processor 101 signals switching network 102 to connect trunk circuit 150 to the communication leads C161 associated with modem 161 to convert the analog signals received from trunk circuit 150 to digital signals. Trunk Data Module (TDM) 160 is connected to modem 161 and serves to connect the digital signal output leads 162 of modem 161 to switching network 102. TDM 160 also interconnects switch processor 101 (via bus 105) and modem 161 to provide various control functions such as: speed setting, select originate/answer mode, hold trunk connection during data call transfer. TDM 160 is connected as a digital endpoint through switching network 102 to adjunct processor 104 and the computer facility as described above for the case of a user access from a port circuit.
While a specific embodiment of the invention has been disclosed, variations in structural detail, within the scope of the appended claims, are possible and are contemplated. There is no intention of limitation to what is contained in the abstract or the exact disclosure as herein presented. The above-described arrangements are only illustrative of the application of the principles of the invention. Normally, other arrangements may be devised by those skilled in the art without departing from the spirit and the scope of the invention. | This adjunct processor arrangement performs a centralized call screening function to provide computer port access security. Every call origination in the telephone switching system from a calling party to a protected computer port is interdicted by the telephone switching system and routed to the adjunct processor. The calling party receives a series of prompts from the adjunct processor to provide identification information, such as login, password, and voiceprint information. The adjunct processor validates the identity of the calling party using this identification indicia and initiates a callback operation. The adjunct processor disconnects the calling party from the connection, calls the calling party back and then uses the data call transfer capability of the telephone switching system to connect the calling party to the computer. | 8 |
BACKGROUND OF THE INVENTION
Can conveying carriages which convey spinning cans, receive several full spinning cans at fiber-sliver producing machines, e.g. draw frames, and convey them to a fiber sliver processing machine are known in spinning operations. The conveying carriages are designed so that they can be positioned at the can discharge location of the fiber sliver producing machine and are able to receive pushed-out cans. The reception is effected in that the can pushed out by the machine is pushed on the conveying carriage and pushes the cans already in place thereon farther by one position. Near the end of the conveying carriage, a signal transmitter is installed on the floor of the spinning shop to signal the machine when a can comes within its range. The signal causes the machine to interrupt the filling of additional spinning cans with fiber sliver since no more capacity is left on the conveying carriage. It is a disadvantage in this device that the signal transmitter is mounted on a rod next to the machine. This rod causes injuries to operators or may be damaged by fork lifts, for example, which circulate in the spinning mill.
OBJECTS AND SUMMARY OF THE INVENTION
It is a principal object of the instant invention to provide a device to signal the fiber sliver producing machine safely when the conveying carriage receiving the spinning can is full and to furthermore considerably increase the safety of the operating personnel and of the device against damage. Additional objects and advantages of the invention will be set forth in part in the following description, or will be obvious from the description, or may be learned through practice of the invention.
The objects are attained through the advantageous embodiments of the present invention. The state of the art and an embodiment of the instant invention are shown in the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a state of the art can conveying carriage at a fiber sliver producing machine;
FIG. 2 shows a can carriage locking device in a top view; and
FIG. 3 shows a can carriage locking device according to FIG. 2, in a cut-away section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are shown in the accompanying drawings. Each example is provided by way of explanation of the invention, and not as a limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the invention without departing from the scope of the invention. Additionally, the numbering of components in the drawings is consistent, with the same components having the same number throughout.
FIG. 1 shows a device according to the state of the art. A fiber sliver is deposited in a can 11 at a spinning mill machine 1. When the can 11 is full, it is pushed out of the spinning mill machine 1 on a conveying carriage 2 over a rail 12. The conveying carriage 2 is designed either as an automotive vehicle or as a hand cart as shown in FIG. 1, and is equipped in that case with a handle 22 for an operator. Supporting rails 23 on which the cans 11 glide are installed on the conveying carriage 2. The can 11 is guided laterally by means of a guide 25.
In order to position the conveying carriage 2 at the spinning mill machine, a method is known by which the conveying carriage 2 is held between a centering unit 3 and a locking unit 4. The top of the conveying carriage 2 is in part broken through in this illustration, so that the centering unit 3 is visible. The centering unit 3 consists of two centering elements 31 which are fixedly attached on the shop floor. Seen in the direction of arrival of the conveying carriage 2, a switch 32 is installed at the end of the centering unit 3. The switch 32 is provided with a pin by means of which a signal is transmitted to the spinning mill machine 1 indicating whether a conveying carriage 2 is available to receive cans 11. If this is not the case, the fiber sliver deposit in additional cans 11 is stopped at the spinning mill machine 1. As the conveying carriage 2 is pushed into the centering unit 3 by means of a pipe 24, the switch 32 is actuated by the pipe 24 on the carriage 2 and the pin 33. As soon as the conveying carriage is centered and positioned, a locking lever 41 of the locking unit 4 engages a lock 21 of the conveying carriage 2. The locking lever 41 is mechanically connected to a swivelling hoop 42 which is installed in the area of the expected spinning cans. The locking unit 4 must therefore be at a sufficient level so that the locking lever 41 on the one hand reaches below the conveying carriage 2 and the swivelling hoop 42 on the other hand is able to sense above the conveying carriage 2 for the presence of spinning cans 11. This locking unit 4 represents a risk of accident because of its necessary structural height.
FIG. 2 shows the structural unit according to the invention which contains a centering and locking unit as well as a signal transmitter for the conveying carriage 2. The centering and locking device 5 is built on a floor plate 51 in the same manner as the signal transmitter. This floor plate 51 must be attached before the spinning mill machine 1 by means of screws 53. The attachment must be such that the can 11 pushed out of the spinning mill machine 1 can be accepted by the conveying carriage 2. The rails 12 must match the supporting rails 23 of the conveying carriage 2 in this case.
The bottom plate 51 is provided with a recess 52 to receive a spring 59 the action of which shall be explained further below. Two centering plates 54 are attached to the bottom plate 51 and are facing each other conically. The shortest distance to the centering plates 54 is near the locking elements 55. If the locking elements 55 have longer sides, the centering plates may also be omitted in another embodiment. The locking elements 55 are installed rotatably on the bottom plate 51 by means of rotation axes 56. The locking elements 55 are provided with an insertion bevel 57 which is aligned with the corresponding centering plate 54. This ensures easy introduction of the pipe 24 into the locking elements 55. The insertion bevel 57 is followed by a locking notch 58. The pipe 24 is held in this locking notch 58 by the centering and locking unit.
The locking elements 55 are pressed against a stop 61 by means of a spring 59. The spring 59 is attached by means of a bolt 60 to the locking element 55. The bolt 60 is either in the position shown in FIG. 2 connected to the locking element 55 or, in order to achieve a modified holding force, is placed in a bore 62 in the locking element 55. Through this modified position, i.e. a modified lever arm in relation to the rotation axis 56 and/or by means a spring with different spring characteristics, the locking force of the locking elements 55 can be adjusted.
A stop 61 is provided to ensure that the insertion bevels 57 are always aligned with the centering plates 54. The two locking elements 55 can be moved only so far towards each other by mens of this stop 61 and via spring 59 that they come into alignment with the centering plates 54.
The switch 32 is furthermore installed on the bottom plate 51. Pin 33 serves as an actuating element and extends into the space between the locking notches 58. As soon as a pipe 24 is present in the space between the locking notches 58, the pin 33 is pressed into the switch 32 and triggers a signal to the spinning mill machine 1, whereby the surrender of the can by the spinning mill machine 1 is made possible. As soon as the pin 33 is in its rest position due to the absence of a pipe 24, the spinning mill machine 1 is informed by signal that the can transfer must be stopped.
The pipe 24 is held in its position in the space between the locking notches 58 which are pressed together with more or less force by the spring 59. This position is maintained for as long as the cans are being pushed on the conveying carriage 2. As soon as the conveying carriage 2 can no longer receive more cans, the last arrived but no longer accepted can 11 pushes the conveying carriage 2 out of the centering and locking unit. Through this the spinning mill machine 1 is informed by signal that no more cans may be received and the production of additional cans is stopped. Depending on need, i.e. depending on the size and weight of the cans 11, a spring 59 with more or less force or a lever arm that is more or less large are selected between the bolt 60 and the rotation axis 56. In each case it must be ensured that the pipe 24 is not moved out of the centering and locking unit 5 during a normal filling process of conveying carriage 2. Only when the carriage 2 is completely full, i.e. when the first can has reached the end of the conveying carriage 2 and is to push the conveying carriage 2 out of the centering and locking device 5 by means of the thrusting force of the lined-up cans and the excess can which has been pushed out, is the pipe 24 allowed to come out of the locking notch 58 and to release the signal via switch 32.
In the instant invention it is especially advantageous that the centering and locking unit 5 is very small and makes the separate locking unit 4 unnecessary. As already described earlier, the separate locking unit 4 has the disadvantage that it was structurally especially high and had to be installed in the shop floor at a relative great distance from the spinning mill machine 1. This increased the risk of accident. Thanks to the centering and locking device 5 of the invention the entire assembly is located in immediate proximity of the spinning mill machine 1 and the risk of accident is thereby lowered considerably.
FIG. 3 shows the essential features of the centering and locking unit 5 of FIG. 2, in a cutaway section A--A. The only difference between the two drawings is that in FIG. 3 a pin 33 does not actuate the switch 32 directly via pipe 24 as in FIG. 2, but that a leaf spring 63 is installed between the pin 33 and the pipe 24. This leaf spring 63 attenuates the actuation of switch 32 by pipe 24. In this manner, the switch 32 is protected against damage since shocks that may be caused by the pipe 24 cannot be transmitted directly to the switch 32 but are attenuated by the leaf spring 63.
As is shown in the drawing of FIG. 3, the spring 59 is set very low so as to let the pipe 24 slide over it. The spring 59 is therefore embedded in part in the bottom plate 51.
The instant invention is not limited to the shown embodiment. Thus for example, the switch 32 in particular may also be made in form of a proximity switch.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. It is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. | Disclosed is a spinning mill machine for the production of fiber sliver and for the deposit of the fiber sliver in spinning cans, with an automatic can replacement device to push out full cans from the machine. A can conveying carriage is centered at the spinning mill machine by means of a centering unit. The can conveying carriage is locked at the machine in order to hold the carriage in a receiving-ready position. A signal transmitter is provided to inform the machine by signal when the can conveying carriage is full. According to the invention the centering unit, the locking unit and the signal transmitter are installed in one single assembly in immediate proximity of the spinning machine. | 3 |
This application is a continuation-in-part of U.S. Ser. No. 08/365,789, filed Dec. 29, 1994, now U.S. Pat. No. 5,535,939 and a continuation-in-part of U.S. Ser. No. 08/365,741, filed Dec. 29, 1994, now U.S. Pat. No. 5,520,321 both of which are divisional applications of U.S. Ser. No. 08/195,067, filed Feb. 14, 1994, now U.S. Pat. No. 5,422,191, issued Jun. 6, 1995.
BACKGROUND OF THE INVENTION
Joining of aluminum by brazing is a well known process due to the strong and uniform joints that can be produced between aluminum parts of varying shapes and types. There are four major brazing processes utilized for the joining of aluminum parts, these are: (a) the flux dip brazing process wherein the parts to be joined are dipped into a molten flux bath utilizing a mixture of chloride and fluoride salts; (b) the furnace brazing process which employs a small amount of flux, for example a chloride salt; (c) the controlled atmosphere brazing process which uses a small amount of fluoridic salt and an inert gas atmosphere, for example nitrogen, argon or helium; and (d) the vacuum brazing method which uses no flux but instead utilizes a reduced pressure atmosphere for the joining of the aluminum parts.
Each of these brazing methods has advantages and disadvantages. For example, the flux dip brazing process is associated with environmental problems arising out of the disposal of the used flux baths. Also, the aluminum parts joined by the flux dip brazing process must be thoroughly cleaned after fluxing to avoid the corrosive effects of the residual flux on the aluminum surfaces.
In the furnace brazing process, much less flux is utilized and the flux is directly deposited on the surfaces of the parts to be joined. Thus, there is no flux bath disposal problem. Nevertheless, the furnace brazing process cannot be readily utilized for the brazing of those aluminum alloys which have a relatively high magnesium content. Typical examples of those alloys which are not readily brazeable by the furnace brazing method are those aluminum alloys which belong to the Aluminum Association 5XXX series.
The controlled atmosphere brazing process employs an inert gas atmosphere, for example argon or nitrogen gas atmosphere, in the brazing furnace. The inert gas atmosphere brazing employs a relatively small quantity of non-corrosive flux which need not be cleaned from the brazed surfaces. The fluoridic flux is expensive and in composite brazing sheets undesirable interactions between the fluoride flux and magnesium limit the maximum core alloy magnesium content to about 0.3%.
In vacuum brazing no flux is employed and the method is suitable for joining those aluminum alloys which contain about 0.1-1.75% by weight magnesium or even more. Due to the magnesium content of the aluminum alloy core, the brazed assembly is capable of exhibiting higher strength properties. Vacuum brazing requires a well sealed furnace, careful control of the pressure within the furnace, both of which may impart higher costs to the brazing process. Additionally, in the vacuum brazing process, assembly tolerances must be critically controlled and the cleanliness of the parts is imperative.
For many applications, especially where strength was a major consideration, the use of aluminum alloys containing magnesium (Mg) up to about 2.00% was desired. Joining of such magnesium-containing alloys by brazing could only be accomplished through use of the vacuum brazing process. Vacuum brazing, however, requires the installation of an expensive vacuum brazing furnace and thus, the process becomes capital intensive.
Those aluminum alloys which are essentially Mg-free cannot be brazed by the vacuum brazing process. Currently, for joining these Mg-free aluminum parts the controlled atmosphere brazing method, employing for example nitrogen atmosphere, is used in the presence of a fluoridic flux. Where brazing of both Mg-free and Mg-containing aluminum alloys was practiced, it was necessary to segregate the different types of alloys and additionally, two different types of furnaces had to be installed, one for controlled atmosphere brazing and the other for vacuum brazing.
Thus, there has been a longstanding need for a filler alloy which could be utilized for the brazing of either magnesium-free or magnesium-containing aluminum alloy parts by controlled atmosphere brazing or by vacuum brazing. Surprisingly, it has been found that an aluminum filler alloy, containing a controlled quantity of magnesium and lithium can be readily employed for the brazing of Mg-free and Mg-containing aluminum alloys using either the controlled atmosphere (inert gas) brazing method or the vacuum brazing process. The aluminum filler alloy of the invention contains from about 0.001% to about 0.4% by weight of magnesium and from about 0.01 to about 0.30% by weight of lithium and as a major alloying element silicon, generally within the limits from about 4 to about 18% by weight of the brazing alloy. The alloy optimally can contain up to ˜1.25% Mn.
It has been recommended in U.S. Pat. No. 3,272,624 (Quaas) to incorporate 0.005-0.010% lithium into aluminum in order to obtain a self-fluxing filler alloy for welding aluminum parts together. The alloy is employed as an extruded or cast wire and is melted during the joining process to obtain a self-fluxing, deoxidizing deposit in the joint area. If desired, up to 18.0% silicon can also be incorporated in the filler alloy. This alloy is employed as a substitute for fluxes containing chloride and fluoride salts since its residue does not need to be removed from the produced joint. Recommended areas of application include carbon arc, oxy-acetylene and inert arc welding. There is no recognition that the presence of the lithium in the aluminum alloy would render it suitable for use as a filler alloy for the brazing of Mg-containing aluminum parts in the presence of fluxes or as a filler alloy in the fluxless vacuum brazing of aluminum components.
U.S. Pat. No. 4,173,302 (Schultze et al) recommends the use of an aluminum brazing alloy which contains 4-20% silicon and between 0.00001 and 1.0% by weight, preferably between 0.005 and 0.1 by weight at least one of the elements of sodium, potassium and lithium. According to this reference the alloy can be utilized in the fluxless brazing of aluminum-containing articles in a non-oxidizing atmosphere or in a low vacuum. The addition of these alkali metals to the brazing alloy is claimed to increase the corrosion-resistance of the brazed joint. The use of these alkali metal-containing brazing alloys is restricted to fluxless, controlled atmosphere brazing and the beneficial effects of these alkali metals are considered equivalent.
U.S. Pat. No. 5,069,980 (Namba et al) describes a clad aluminum alloy suitable for fluxless vacuum brazing. The cladding material is to be used on both sides of a core sheet. It contains 6-14% silicon, 0.06% magnesium, balance aluminum and additionally, at least one of the following elements may also be incorporated in the cladding alloy for the improvement of its corrosion-resistance: Pb, Sn, Ni, Cu, Zn, Be, Li and Ge. The role of these additives in the alloy are equated as far as their corrosion-resistance improving effect is concerned.
It has surprisingly been discovered that the presence of lithium in combination with magnesium in the filler alloy, when added in controlled amounts within the range from about 0.01 to about 0.3% by weight lithium and 0.05 to 0.4% by weight magnesium, allows the use of the filler alloy for brazing either by the controlled atmosphere brazing method or by the vacuum brazing process, as well as other conventional brazing processes.
The universal applicability of the filler alloy of the invention for the brazing of both magnesium-containing and magnesium-free aluminum alloys eliminates the need to segregate these alloys and further provides the freedom to use a wide range of conventional brazing processes desired by the manufacturer of brazed aluminum assemblies.
SUMMARY OF THE INVENTION
The present invention provides a filler alloy for brazing, which includes about 4 to 18 wt. % silicon; about 0.001 to 0.4 wt. % magnesium; about 0.01 to 0.3 wt. % lithium; not more than about 2 wt. % zinc; not more than about 1.25 wt. % manganese; not more than about 0.30 wt. % iron; not more than about 0.10 wt. % copper; not more than 0.15 wt. % impurities; balance aluminum. Alternatively, the invention provides a brazing sheet composite wherein the filler alloy cladding is applied to an aluminum core alloy material.
In an alternative embodiment, the invention provides a process of joining aluminum parts by brazing to produce an assembly. The process comprises providing the brazing sheet composite, contacting an aluminum part with the filler alloy cladding; and brazing the aluminum part and the composite sheet to produce a brazed assembly.
The foregoing and other objects, features, and advantages of the invention will become more readily apparent from the following detailed description of preferred embodiment which proceeds with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a graphically shows the effect of lithium level on the joint size of vacuum brazed vertical fin pack, according to the present invention.
FIG. 1b graphically shows the effect of magnesium level on the joint size of vacuum brazed vertical fin pack, according to the present invention.
FIG. 2a graphically shows the effect of lithium content on the size of fluoridic flux brazed mini-radiator joints, according to the present invention.
FIG. 2b graphically shows the effect of magnesium content on the size of fluoridic flux brazed mini-radiator joints, according to the present invention.
FIG. 3 graphically shows the effect of lithium level on a vacuum brazed horizontal wedge tee joint size at a constant magnesium level of 0.2 wt. %, according to the present invention.
FIG. 4. graphically shows the effect of various alloying elements on fillet formation test sample length, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to the brazing of aluminum articles. More particularly, this invention relates to a novel Mg and Li-containing aluminum filler alloy suitable for the brazing of both Mg-free and Mg-containing aluminum alloy articles by either the controlled atmosphere brazing process or by the vacuum brazing method.
For the purposes of this invention, and as used hereinafter, the terms "controlled atmosphere brazing" or "CAB" refer to a brazing process which utilizes an inert atmosphere, for example nitrogen, argon or helium in the brazing of aluminum alloy articles.
The term "vacuum brazing" as used herein refers to a process which employs reduced pressure in the brazing of aluminum alloy articles.
The filler alloy of the present invention, whether or not its use is in the controlled atmosphere brazing process or in the vacuum brazing process, contains from about 0.01 to about 0.3% lithium. In addition to the lithium content, the filler alloy also contains from about 0.001% to about 0.4% magnesium and from about 4 to about 18% Si. The filler alloy may also contain additional constituents, for example, zinc up to about 2%, manganese up to about 1.25%, iron in amounts up to about 0.30% and copper up to about 0.10%. The aluminum filler alloy generally also contains the usual unavoidable impurities up to a total amount of about 0.15%. Most preferably, the filler alloy of the present invention comprises from about 0.01 to 0.3 wt. % lithium and from about 0.001 to 0.4 wt. % magnesium.
In the event the filler alloy is employed in the CAB process, for example in combination with the well-known fluoridic flux, the lithium content of the filler alloy is preferably maintained within the range from about 0.01 to about 0.3% and the magnesium content is preferably maintained within the range from about 0.001% to about 0.4%. Variations of the flux can be employed. For example, the flux can contain LiF to further improve the brazeability. This alloy can be used with any controlled atmosphere brazing process in which any flux or pretreatment is employed.
The novel filler alloy is generally employed in the form of a brazing sheet rolled from ingots having the desired alloy composition. Regardless of which brazing process the brazing sheet is going to be used in, for best results it is applied to the surface of the aluminum core alloy through cladding. Cladding of the aluminum core alloy with the brazing sheet is accomplished by methods well-known in the art, for example by pressure welding through a rolling process. Depending on the assembly to be made the brazing or filler alloy sheet may be applied to one or both sides of the aluminum core alloy. The thickness of the brazing sheet applied to one or both surfaces of the core alloy is usually within the range from about 5 to about 20% of the thickness of the aluminum composite. Thus, for example, if the thickness of the aluminum composite is about 0.1 inch (2.54 mm), then the thickness of the cladding applied to the surface of the aluminum core can vary between 0.005 and 0.020 inch (0.127-0.508 mm).
The types of aluminum core alloys, which are clad with the novel filler or brazing alloy sheet, are generally selected on the basis of the end use of the brazed assembly. Suitable aluminum core alloys which can be clad with the novel filler alloy composition include those aluminum alloys which are classified as 1XXX, 3XXX, 5XXX and 6XXX aluminum alloys by the Aluminum Association, the 3XXX alloys being preferred.
The clad aluminum composite may be subjected to a heat treatment to improve its physical properties. Thus, the clad composites of the present invention may be subjected to a heat treatment equivalent, for example, to H-temper.
The clad aluminum alloy compositions of the present invention can be readily employed for making brazed heat exchanger assemblies, such as radiators and components for such heat exchangers. Other applications are also possible, for example, utilization of the aluminum alloy brazing composition in the manufacture of evaporators.
The brazing of the assemblies made from the aluminum core alloys clad with the Mg and Li-containing brazing sheet is accomplished according to principles well-known in the brazing art. For example, in the CAB process, flux can be applied to the aluminum parts to be joined, then the assembly is preheated, for example to a temperature in the range from about 425°475° F. (224°-246° C.). The assembly is then transferred to a prebraze chamber where it is soaked for about 3-15 minutes at about 750° F. (399° C.). Subsequently, the hot assembly is transferred to the brazing furnace which is purged with dry nitrogen. The assembly is kept then for 2-3 minutes at about 1095° F.-1130° F. (591° C.-610° C.) in the CAB furnace. The brazed assembly is then cooled, removed, and applied for its intended use.
If the vacuum brazing process is utilized for the joining of aluminum parts, no flux is applied to the joint area. The assembly to be brazed is usually preheated to about 425°-700° F. (224°-371° C.) and then introduced into the vacuum furnace. In the vacuum furnace, the preheated assembly is heated in stages to about 1095°-1120° F. (591°-604° C.) and then kept at temperature for about 3 minutes. Subsequently, the brazed assembly is cooled to about 1050°-1070° (566°-577° C.) and then removed from the vacuum furnace to be used for its intended purpose.
In the case of Mg-containing and also Mg-free aluminum core alloys, regardless of the brazing methods applied, the strengths of joints formed as measured by the area, weight or length of the filler in the joints of the assemblies, are substantially the same. This fact indicates that the novel filler alloy can be readily employed for the production of vacuum or CAB brazed assemblies made from both Mg-free and Mg-containing aluminum core alloys.
The following examples will further demonstrate the unique brazing capability of the magnesium and lithium-containing filler alloy and the applicability of such filler alloy for the brazing of both Mg-free and Mg-containing alloys using either the CAB method or the vacuum brazing process. Those skilled in the art will appreciate that the alloy of the present invention can also be used in dip brazing, furnace brazing, and brazing by torch heating, induction heating, resistance heating and other suitable means for achieving temperatures required for brazing.
EXAMPLE 1
Experiments were conducted to establish the effectiveness of the novel filler alloy for the production of satisfactory brazed joints between Mg-containing aluminum core alloy parts. The experiments were conducted by brazing test assemblies by both the vacuum brazing and controlled atmosphere brazing methods.
Aluminum brazing sheets, having a thickness of 0.015 inch (0.381 mm), were roll clad on one side with the filler alloys having varying lithium contents and an overall composition shown in Table 1. The cladding layer on the cores was equivalent to about 10% of the total thickness of the clad composite. The composites were partially annealed to the H24 temper in dry nitrogen at about 540° F. (282° C.) for a time period of about 4 hours. The partially annealed core alloy-filler alloy composites were then used to make the test samples which were then brazed together by the vacuum brazing method and also by the controlled atmosphere brazing method under conditions described below.
TABLE 1______________________________________Typical Composition of the Li-containing Filler AlloyElement Weight %______________________________________Li 0.01-0.30Si 9.50Fe 0.30Cu 0.10Mn 1.25(from 1.0)Mg 0.05-0.61Zn 0.08Others (total) 0.15Balance aluminum______________________________________
Two types of samples were examined. First the mini-radiator experimental sample to simulate tube-to-header joints. The other sample was the vertical fin pack sample that was used to determine how well tube-to-fin type joints were made. The mini-radiator sample was coated with a fluoridic flux and controlled atmosphere brazed. The vertical fin pack samples were vacuum brazed; no flux was employed. The filler metal alloys used for these studies were developed to study the effect of Mg, Mn, and Li. Based on the results of our studies, increasing Li levels, up to about 0.05% (by weight) result in progressively larger fillets. Beyond this range, the fillet size becomes smaller. Although the fillet sizes decrease past the optimum Li level, the fillet sizes at 0.3% Li are equal to or larger than the control materials, which contain no Li or Mn. Brazing of the assemblies proceeded as follows:
(a) Vacuum Brazing
The degreased fin pack assemblies were preheated in vacuum to 450° F. (232° C.) for 5 minutes, then they were transferred to the vacuum brazing furnace chamber where they were step-wise heated at first to 1000° F. (538° C.) in 10 minutes, then to 1095°-1120° F. (590°-604° C.) in 6 minutes. The assemblies are then kept within the 1095°-1120° F. (590°-604° C.) range for about 3 minutes, then cooled. The relationship between filler metal Mg and Li levels on the vacuum brazed vertical fin pack fillet sizes are described in Table 2 and graphically in FIGS. 1a and 1b.
TABLE 2__________________________________________________________________________Results from the vertical fin pack test samples described in Example 1CFT IDControl 90-130 93-6-16 93-6-22 91-137-3 91-137-6 91-137-7 91-137-8 91-137-9 91-137-10__________________________________________________________________________% Li 0.000 0.100 0.250 0.013 0.030 0.010 0.000 0.025 0.014% Mg 0.200 0.200 0.200 0.610 0.190 0.179 0.640 0.508 0.173% Mn 0.001 0.001 0.001 0.001 1.270 1.000 0.960 0.976 0.005Joint No.1 0.0761 0.0586 0.0734 0.1252 0.0756 0.0793 0.0779 0.0876 0.11302 0.0745 0.0597 0.0757 0.1110 0.0775 0.0789 0.0775 0.0881 0.11183 0.0767 0.0573 0.0721 0.1285 0.0751 0.0603 0.0753 0.0889 0.11034 0.0768 0.0559 0.0714 0.1282 0.0727 0.0597 0.0740 0.0895 0.10905 0.0750 0.0573 0.0723 0.1192 0.0789 0.0828 0.0850 0.0895 0.11066 0.0765 0.0582 0.0688 0.1169 0.0791 0.0831 0.0814 0.0901 0.11197 0.0768 0.0591 0.0714 0.1194 0.0742 0.0811 0.0819 0.0868 0.11028 0.0775 0.0598 0.0717 0.1177 0.0734 0.0811 0.0881 0.1070__________________________________________________________________________
Magnesium additions of at least 0.2% are considered requisite for successful vacuum brazing. In this work, we found that Li+Mg results in larger fillets than when Mg or Li is added individually, as shown in FIGS. 1a and 1b. However, manganese (Mn), has effect on the joint size. In FIGS. 1a and 1b, it is clear the when the Mn level reaches about 1.00% to 1.25%, the fillet size is decreased to a level that is only slightly better than the control materials, which contain less than 0.05% Mn. Although Mn decreases the size of the largest fillets developed in the Li+Mg alloys that were vacuum brazed, it does not appear to have the same effect in CAB.
(b) Controlled Atmosphere Brazing
A flux was deposited on the surface of the degreased assemblies in an amount corresponding to about 5 grams/ 2 surface. The fluxed assemblies were preheated to 450° F. (232° C.) for 15 minutes then transferred to the prebraze chamber where they were soaked at 750° F. (399° C.) for 10 minutes. Subsequently, the preheated assemblies were transferred to the braze chamber (which was purged for 2 hours with dry N 2 prior to the brazing) where they were kept at about 1100° F. (593° C.) for 3 minutes and then removed.
The effect of the filler metal Mg and Li levels on the mini-radiator tube-to-header joint sizes are described in Table 3 and have been plotted in FIGS. 2a and 2b.
TABLE 3______________________________________Effect of filler metal Mg, Li and Mn levels on thefillet sizes of the mini-radiator samples described in Example 1 95-200,CFT ID Control 91-137-3 91-137-6 91-137-9 91-137-10______________________________________% Li 0.0000 0.013 0.030 0.025 0.014% Mg 0.0000 0.610 0.190 0.508 0.173% Mn 0.0000 0.001 1.270 0.976 0.005Fillet No. 1 0.0696 0.0000 0.3588 0.0000 0.3149 2 0.0453 0.8706 0.3069 0.4839 0.2302 3 0.0154 0.0000 0.3175 0.1802 0.4812 4 0.0590 0.0000 0.3320 0.6364 0.3920 5 0.0603 0.3672 0.3748 0.0421 0.3147 6 0.0549 0.0000 0.3820 0.6412 0.4256 7 0.0509 0.0491 0.3790 0.7106 0.2757 8 0.0691 0.7571 0.3127 0.2851 0.4389 9 0.0388 0.3136 0.1870 0.4100 0.377910 0.0291 0.0396 0.3491 0.7298 0.313211 0.0644 0.8818 0.3788 0.0000 0.505312 0.0824 0.0461 0.4140 0.6810 0.305113 0.0264 0.3657 0.2097 0.0277 0.425914 0.0768 0.0801 0.3271 0.0252 0.370815 0.0352 0.0000 0.2853 0.6519 0.372516 0.0339 0.0000 0.2934 0.3542 0.357117 0.1791 0.7745 0.2972 0.0000 0.062318 0.1642 0.0255 0.3643 0.3713 0.153419 0.0419 0.1092 0.3284 0.0306 0.257220 0.0508 0.1516 0.3892 0.3134 0.420321 0.0460 0.0316 0.3210 0.1196 0.271022 0.0653 0.0839 0.3582 0.3878 0.381523 0.0673 0.0674 0.3772 0.2638 0.335824 0.0648 0.0000 0.3993 0.3212 0.356525 0.075326 0.094027 0.183728 0.213729 0.087630 0.046231 0.232732 0.2284______________________________________
Surprisingly, we found that filler metals that also contain Mg, in addition to Li, can be controlled atmosphere brazed. We found that if Li is present in the filler metal, Mg levels up to about 0.4% can be brazed successfully, i.e., uniform fillets that are stitch-free. In FIGS. 2a and 2b, we have shown that the average fillet size for the new Li-Mg filler metals are larger than the control alloys, however, we must also look at the size of the error bars shown around these points (i.e., the 0.508% Mg and 0.61% Mg). Typically, as the span of the error bars increases, the more irregular the fillet size. Some of the joints in these high Mg samples developed very large fillets on one side of the joint, but the other side had no joint. Although the fillet size increased in CAB samples that contained high levels of Mg and a low level of Li, these samples were considered impractical for commercial use. As was noted above, Mn does not appear to affect the brazeability of the Li+Mg alloys, as shown in FIGS. 2a and 2b.
EXAMPLE 2
In another example, horizontal wedge tee samples were made with a filler metal containing 0.2% Mg (by weight) and varying levels of Li. These samples were vacuum brazed using the cycle described in Example 1. The results of this test are described in Table 4 and graphically in FIG. 3.
TABLE 4__________________________________________________________________________Vacuum brazed horizontal wedge tee fillet sizes as a function of fillermetal Li level as described in Example 2CFT IDControl 90-130 93-6-7 93-6-16 93-6-22 90-87-1 91-136-12 91-136-14 91-136-16 91-136-18__________________________________________________________________________% Li 0.000 0.013 0.100 0.250 0.000 0.014 0.015 0.017 0.021% Mg 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200% Mn 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001Joint No.1 0.0232 0.1054 0.0521 0.0499 0.0306 0.0924 0.0828 0.0902 0.08092 0.0306 0.0908 0.0471 0.0590 0.0345 0.1040 0.0863 0.0900 0.09313 0.0402 0.0889 0.0513 0.0609 0.0264 0.1002 0.0805 0.0893 0.08814 0.0444 0.0868 0.0417 0.0487 0.0284 0.1009 0.0848 0.0151 0.08615 0.0333 0.1029 0.0941 0.0889 0.09056 0.1008 0.0798 0.0901 0.03067 0.1048 0.0777 0.1026 0.08368 0.1000 0.0863 0.0844 0.0901__________________________________________________________________________
EXAMPLE 3
Vacuum brazing tests were also conducted to compare the effects of substituting lithium with calcium, sodium and beryllium in the filler alloy. Thus, samples were prepared by replacing the lithium content of the filler alloy composition shown in Table 5 with substantially equivalent quantities of calcium, sodium and beryllium. For comparison, a lithium-containing sample was also used. The Li, Pb, Sn, Na, Mg, In, Sb, Fe, Ti, Zr, and Bi-containing filler alloys were then tested by measuring the fillet lengths formed when subjected to a conventional test based on the comparison of their respective surface tension which is a measure of brazeability. It was found that the fillet lengths and thus the strength properties of the fillets formed from the sodium and beryllium-containing filler alloys were significantly below the strength level of the lithium-containing filler alloy. The results of the comparative tests performed with Li, Pb, Sn, Na, Mg, In, Sb, Fe, Ti, Zr, and Bi-containing filler alloys are graphically depicted in FIG. 4.
TABLE 5______________________________________Fillet formation sample test results. All samples were vacuum brazed.Filler Alloy + Fillet Length Fillet Length Average(AA4045 with 0.2% Mg +) inches inches Fillet Length(Measured Additions) A-Sample B-Sample inches______________________________________Control, No Additions 0.37 0.10 0.240.11% Li 0.83 0.80 0.810.25% Li 0.65 0.73 0.690.13% Bi 0.29 0.32 0.310.89% Pb 0.35 0.27 0.310.42% Sn + 0.83% Pb 0.21 0.25 0.230.56% Sb 0.30 0.25 0.280.77% Sn 0.25 0.25 0.250.93% In 0.20 0.28 0.240.36% Mg 0.22 0.29 0.260.15% Li + 0.40% Mg 0.90 0.65 0.780.03% Na 0.27 0.27 0.270.18% Ti 0.17 0.20 0.190.97% Fe 0.13 0.08 0.100.19% Zr 0.22 0.20 0.21______________________________________
Having illustrated and described the principles of our invention in a preferred embodiment thereof, it should be readily apparent to those skilled in the art that the invention can be modified in arrangement and detail without departing from such principles. We claim all modifications coming within the spirit and scope of the accompanying claims. | The present invention provides a method of joining aluminum parts by brazing, comprising the steps of (a) providing a composite sheet having an aluminum core alloy material and a filler alloy cladding, applied to the core alloy material, the cladding including about filler alloy for brazing, which includes about 4 to 18 wt. % silicon, about 0.001 to 0.4 wt. % magnesium, about 0.01 to 0.3 wt. % lithium, not more than about 2 wt. % zinc, not more than about 1.25 wt. % manganese, not more than about 0.30 wt. % iron, not more than about 0.10 wt. % copper, not more than 0.15 wt. % impurities, balance aluminum; (b) contacting an aluminum part with the filler alloy cladding; and (c) brazing the aluminum part and the composite sheet to produce a brazed assembly. | 8 |
BACKGROUND OF THE INVENTION
It is well known that turbocharged diesel engines yield a puff of smoke when accelerated rapidly from a low speed and/or low load condition. This results from the inability of the turbocharger to keep pace with the increase in fuel supplied during acceleration. The result is a temporary fuel-rich combustion which produces a "puff" of exhaust smoke.
Due to environmental concerns, particularly in recent times, various approaches have been made with various degrees of success to minimize this problem which otherwise, especially in vehicle applications, would cause turbocharged diesel engines to be objectionable. One of the approaches is based on the use of a pneumatic device that limits the fuel quantity to a low level whenever the air pressure in the intake manifold is low and allows for more fuel quantity (up to a preset fixed fuel schedule) as the pressure increases. Even though this approach is fairly simple and has produced some success in the control of acceleration smoke, it is rather restrictive on engine torque available during acceleration. The reason is that during acceleration the turbocharger has to speed up and develop a sufficient pressure before the device can start responding and allow for any increase in the fuel flow. Until such time, the engine torque is limited to a minimum. During acceleration the torque increase always lags behind the turbocharger, a characteristic inherent to pressure sensing puff limiting devices.
SUMMARY OF THE INVENTION
The present invention overcomes the problems noted above that are associated with the acceleration of diesel engines. More particularly, the invention concerns a control device that serves to limit the rate of increase of the amount of fuel supplied to the engine during periods of acceleration and/or increase of load so that the amount of fuel actually passed into the engine cylinders, at any point of time, corresponds more closely to that which is appropriate for combustion with the increasing amount of available air without producing undue amounts of exhaust smoke. This control device can, for convenience, be referred to as a smoke or puff limiter.
Most diesel engines are equipped with a system for supplying fuel to the engine cylinders that includes a fuel injection device having a projecting control rack whose linear position or displacement corresponds to the amount of fuel being delivered to the engine cylinders. The smoke limiter of the present invention serves to control fuel flow to the engine by fluidly restricting the rate of displacement of the fuel injection control rack so that the rate of increase of the amount of fuel delivered to the engine corresponds more closely to the rate of increase of the amount of air that is delivered to the engine cylinders by the accelerating turbocharger even though the operator of the engine may reset the engine accelerator or governor into a position of a greater amount of fuel more rapidly.
More particularly, movement of the fuel injection control rack towards positions of greater fuel delivery is resisted by the biasing force of a pressure-actuated, hydraulic piston having liquid contained in at least two chambers between which fluid flow is restricted. The rate at which this biasing force is overcome to permit greater displacement of the fuel injection control rack for greater fuel delivery, is primarily a function of the pressure delivered by the control rack force and the rate of the restricted fluid flow between the chambers in response to such pressure. Additionally, the intake manifold pressure is applied towards overcoming the biasing force of the fluid piston, primarily in order to prevent the smoke limiter from affecting the fuel injection control rate when turbocharger acceleration is completed and a sufficient intake manifold pressure is reached for a particular fuel flow. This assures that there is no distrubing force acting on the fuel injection control rack and that the governor regains full control of the engine at steady state operating conditions.
As the forces counteracting the biasing force of the fluid piston towards restriction of control rack movement increase during a period of engine acceleration, the biasing force against the fuel pump control rack decreases to permit greater displacement of the rack towards positions of greater fuel delivery to the engine. In this manner the amounts of fuel and combustion air supplied to the engine cylinders more closely correspond to the ratio needed to avoid insufficient combustion and undue exhaust smoke. Thus, the rate of fuel increase to the engine cylinders has a schedule that is better suited to the acceleration in the amount of combustion air supplied to the engine. The smoke limiter is operatively engaged with the fuel injection control rack at low manifold pressure and high fuel quantity demand, and is disengaged at steady state operating conditions when intake manifold pressures are sufficient for any given fuel flow.
The engine control method and apparatus of the invention can be embodied in the forms shown in the drawings and described in appropriate detail below. In a general sense, movement of the fuel injection control rack to positions of greater fuel delivery is restricted by contact with a rod or shaft extending from the smoke limiter. The extending rod is moved linearly by the pressure-actuated, biasing force of a fluid piston. The fluid is divided between enclosed chambers and fluid flow is permitted between the chambers. Such flow is more restricted in the direction permitting greater control rack displacement and, therefore, greater fuel delivery to the engine. A principal controlling force for this movement of fluid is the applied force of the fuel injection control rack. The device is constructed so that at the intake manifold pressure corresponding to engine steady state operating conditions contact between the control rack and the rod extending from smoke limiter is disengaged and remains so until a sequence of sufficiently low intake manifold pressure followed by a sufficient and rapid acceleration and/or increase of load takes place. During movement of the fuel injection control rack towards a position of lesser extension from the fuel injection controller and lesser fuel delivery, liquid in a chamber of the fluid piston moves relatively freely back into the chamber from which there had been restricted flow during engine acceleration. The smoke limiter is thereby placed in a position to again control engine acceleration and reduce the amount of exhaust smoke during such acceleration periods.
The method and apparatus of the invention, therefore, provide for simple and effective, fluid control of the schedule of fuel supplied to the cylinders of a diesel engine during acceleration. Accordingly, the discharge of undue smoke into the atmosphere and its polluting effects can be effectively reduced. Moreover, the device can be readily adapted for use with existing engines with a minimum of expense and alteration and with little, if any, adverse effect on the operation of the engine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the smoke limiter in conjunction with the engine components related to the smoke control process.
FIG. 2 is a cross-sectional view of one embodiment of the control apparatus.
FIG. 3 is a cross-sectional view of another embodiment of the control apparatus taken along lines 3--3 of FIG. 5.
FIG. 4 is a cross-sectional view of the control apparatus taken along lines 4--4 of FIG. 5.
FIG. 5 is a side view of the apparatus shown in FIGS. 3 and 4.
FIG. 6 is a cross-sectional view of another control apparatus of the invention.
FIG. 7 is a cross-section view of a fourth embodiment showing a refillable control apparatus.
FIG. 8 is a cross-section view of a fifth embodiment showing another type of refillable control apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there are shown some of the elements typically employed in controlling the fuel and air delivery to internal combustion engine, particularly diesel engines. Fuel pump 2, is employed with the engine to pump the fuel under pressure into each individual cylinder. For controlling the fuel flow, a control rack 4 is integrated with the fuel pump of the injection system and an actuating means such as a governor and accelerator to change the operation of the fuel pump and ultimately the flow of fuel. A manifold 6 receives air under pressure from turbocharger 8 and distributes the air to each individual cylinder for combustion with the fuel provided by the fuel pump. The smoke limiter 10 acts with the foregoing members to control the increase in fuel flow during acceleration so that a schedule of increase in fuel flow corresponds more closely with the rate of turbocharger acceleration to reduce engine smoke. As shown in FIG. 2, movement of the control rack to the right indicates increase in fuel flow while movement of the control rack in the opposite direction corresponds to a decrease in fuel flow. Smoke limiter 10 includes a housing 12 with a locating rod or shaft 14 movable relative to the housing and having an exposed end 15 for engaging the control rack 4 at different positions along the path of movement of control rack 4, at least partly, as a function of the manifold pressure. The other end 17 of the locating shaft 14 is secured to a piston 16 which moves within the housing 12.
As can be seen in FIG. 2, housing 12 is divided into two chambers 34, 36 by a wall member 18. A relatively large passage 20 extends through the wall 18 and establishes a flow path between the two chambers formed by the wall. A check valve 27 includes a flexible plate 24 attached to the left side of wall 18 by rivet 26, such that plate 24 can only flex or bend away from passage 20 toward the left or chamber 34. An orifice 28 is provided in the plate 24 in communication with the passage 20. Orifice 28 is substantially smaller than the passage 20 to significantly restrict the flow rate of fluid from the left or first chamber 34 to the right or second chamber 36 which houses piston 30 for movement therein. With this configuration, when fluid is pressurized in a manner which causes flow from the second chamber 36 to first chamber 34, the plate will bend away from the passage 20 to allow increase in fluid flow over that which would otherwise occur if it had to flow solely through the orifice 28. On the other hand, when the pressure is reversed, plate 24 is pressed against the wall 18 and fluid is permitted to flow only through orifice 28 at a much reduced rate.
The movement of the fluid through the orifice 28 in the passage 20 in cooperation with the intake manifold pressure and the other elements of the smoke limiter 10 serve to position the locating shaft 14 along the path of movement of the control rack 4 depending on the intake manifold pressure as well as to define the schedule for movement of the control rack once it has engaged the locating shaft during acceleration. To achieve this purpose, the pistons are arranged in sealing relationship with the side walls of the chambers defined in the housing. Specifically, with reference to FIG. 2, an outer surface of piston 16 is connected to a flexible first diaphragm 40 of the rolling type and the back side of piston 16 is fixed to locating shaft 14. Diaphragm 40 is sealed to the side walls of first chamber 34 approximately midway between the left end and wall 18 of housing 12. To maintain piston 16 in contact with diaphragm 40, an optional auxiliary spring 41 is employed; but, such contact can be secured by any other convenient means. First diaphragm 40 is one which allows movement equal to the stroke of the shaft 14 within chamber 34. Intake manifold pressure port 38 is provided through the exterior of housing 12 to expose the rear side of piston 16 to manifold pressure with the forward side of the piston being in communication with fluid in first chamber 34. Similarly, second piston 30 includes a flexible seal of the rolling diaphragm type to form a second diaphragm 42 in sealing engagement with the internal walls of housing 10 at a position approximately midway between the right end of the housing and wall 18. Mainspring 32 is included between piston 30 and the right end of housing 10 to continuously bias piston 30 in a direction toward wall 18 and first piston 16. The rear side of the piston 30 is exposed to the atmosphere through vent 46 in the right end of the housing while the front portion of the second diaphragm 42 is in communication with the fluid in second chamber 36.
The force developed by mainspring 32 on second piston 30 is designed so that when manifold pressure on first piston 16 is sufficiently low and relatively little or no force is developed by control rack 4 on locating shaft 14, spring 32 acting on piston 30 imparts pressure on the liquid in chamber 36 high enough for the check valve 27 to open and liquid to flow relatively rapidly into first chamber 34. This action will overcome the force of spring 41 until shaft 14 is fully extended. There are intermediate positions where the manifold pressure is such that pressure imparted to piston 16 through port 38 will equal that produced by the main spring 32. This equilibrium situation will stop movement of piston 16 and ultimately shaft 14. This movement to the left caused by the action of main spring 32 is referred to as the return action of the puff limiter.
Spring 32 acting on second piston 30 will be compressed under the action of the control rack force applied to the locating shaft 14, to raise the pressure in chamber 36. This is accomplished by forcing the liquid in first chamber 34 under pressure of piston 16 through orifice 28 into second chamber 36. Because the flow of liquid through orifice 28 is relatively slow, the movement of piston 16 through chamber 34 is restricted from what it would be otherwise; correspondingly, the movement of control rod 4 is restricted during those periods of acceleration when it is engaged with shaft 14. This restriction of movement will continue until travel of locating shaft 14 under the action of control rod 4 has ceased in the direction of increased fuel flow. The rate of this process, which is controlled by the orifice size and the pressures on the fluid within the chambers, is matched with the rate of turbocharger acceleration so that the engine's exhaust smoke is acceptable.
During acceleration, increase in fuel flow is accompanied by a corresponding increase in manifold pressure. The exposure to this pressure of piston 16 aids in the completion of shaft retraction; however, the main purpose of this manifold pressure is to disengage the puff limiter locating shaft 14 from the control rack 4. The latter feature keeps the puff limiter 10 out of contact with control rack when steady-state turbocharger speed is achieved even though the force of control rack 4 on shaft 14 disappears. Thus, the manifold pressure on piston 16 acts as a locator in conjunction with spring 32 to position shaft 14 at different points in the path of travel of control rod 4 as a function of fuel flow.
The following is a general explanation of the operation of the above-described puff limiter. At idle, the manifold pressure and the fuel flow are low, therefore the puff limiter locating shaft 14 is fully extended under the action of spring 32 applying pressure in the liquid to force piston 16 leftward. The control rack 4 is positioned away from shaft 14 as dictated by an injection system governor. When the engine is commanded to accelerate, the governor causes control rack 4 to move rapidly toward maximum fuel flow until rack 4 impacts on extended locating shaft 14. At that impact or engagement, the control rack 4 encounters a resistance developed by the puff limiter. This resistance is caused by piston 16 being engaged with the liquid in chamber 34 and forcing it at a very slow rate through orifice 28. This resistance force is generated by a pressure difference between chambers 36 and 34 as liquid flows through orifice 28. The control rack 4 velocity will be slowed to a level which is dictated by the balance between the governor force exerted on control rack 4 and the resisting force of puff limiter 10.
During this acceleration period, an increase in intake manifold pressure is developed by the accelerating turbocharger. Correspondingly, there is an increase in the retracting force acting on shaft 14 and in the resulting rate of retraction until a point is reached where the governor will stop further fuel flow increase. At this point, the puff limiter locating shaft 14 separates from control rack 4 and keeps retracting due to intake manifold pressure until either equilibrium of forces of the intake manifold pressure and the mainspring 32 are achieved or a full puff limiter stroke is achieved.
When the engine is commanded to rapidly decelerate, for example during a gear shift, the governor causes control rack 4 to move rapidly toward the left, a no-fuel position. Under these conditions, where the movement of control rack 4 to the left is greater than that of locating shaft 14, control rack 4 will remain disengaged from locating shaft 14. During deceleration, the turbocharger speed is reduced, and, therefore, the intake manifold pressure is reduced. This, of course, is reflected on the rear side of piston 16 allowing mainspring 32 force to overcome the manifold pressure force on piston 16. Specifically, there is a departure from equilibrium position to a condition where the pressure in chamber 34 is lowered relative to that in 36. Thus, liquid under pressure of piston 30, which in turn is biased by spring 32, will flow through passage 20 into chamber 34. This displaces piston 16 to the left and moves shaft 14 toward a fully extended position. Since the check valve 27 opens during this process the flow of liquid from chamber 36 to chamber 34 occurs much more rapidly than in the reverse direction. As a result, travel of shaft 14 toward the extended position occurs more rapidly than retraction, and the puff limiter becomes ready to perform the control steps of the next acceleration cycle. The amount of extension depends on the residual manifold pressure at the end of deceleration. The more pressure, the less shaft extension, which means more of engine torque is immediately available at the beginning of the next acceleration cycle. But even if the shaft is fully extended as would be the case in a long period of time for a gear shift, only little or no torque reduction can be noticed during the subsequent acceleration since the puff limiter locating shaft 14 then starts retracting without any hesitation and full engine torque operation is achieved in a few seconds.
In FIGS. 1 and 2, a preferred embodiment is shown in which the housing 12 is cylindrical in configuration with pistons 30 and 16 both moving along a common longitudinal axis. Another embodiment which works in substantially the same way as the embodiment described above is shown in FIGS. 3-5. The reference numbers used in discussing the embodiment shown in FIGS. 3-5 are primed to distinguish them from the reference numerals used in FIGS. 1 and 2. Similar reference numbers, represent like parts in each embodiment.
The smoke limiter 10' of the embodiment shown in FIGS. 3 to 5 includes a first piston 16' having a first diaphragm 40' for movement in a first chamber 34'. Similarly, a second piston 30' having a second diaphragm 42' moves in second chamber 36'. The rear side of piston 16' is exposed to manifold inlet pressure through intake manifold pressure port 38'. Unlike the embodiment discussed above, the movement of pistons 16', 30' as well as the configuration of housing 12' are not symmetrical. The portion of housing 12' defining second chamber 36', as can be seen in FIG. 3, is substantially at right angles to that portion of housing 12' defining first chamber 34'. Accordingly, wall member 18' extends along the top portion of first chamber 34' rather than being perpendicular to the common axis of piston movement shown in FIG. 2. In addition, check valve 27' is located at the end of chamber 34' in wall 19' perpendicular to wall member 18' and is connected to chamber 36' through vertical conduit 60'.
The check valve 27' has a different configuration than that described in connection with FIG. 1. Specifically, check valve 27' includes two passages parallel to the axis of travel for first piston 16', parallel to one another, and displaced from the axis of the first chamber of the housing 12' having first chamber 34'. In chamber 34', a cup member 52' completely encompasses the passages 50' and, in addition, defines two cup passages 54' parallel to one another and parallel to but displaced from passages 50'. In this way, a protective cover is provided for the passages as well as other elements of the valve described hereinafter while still allowing flow of fluid therethrough.
Fixed to inner surface 33' at the end of chamber 34' is a flexible, dome-shaped valve member 56' having an outer periphery 58' which encompasses passages 50'. The dome-shaped member 56' is sufficiently flexible that when fluid is placed under pressure in chamber 36' greater than that in chamber 34', the periphery 58' will be forced away from the surface allowing the fluid to flow around the dome-shaped member and through the cup passages 54'. On the other hand, where the pressure in chamber 34' is greater than that in 36', the periphery will be forced flush against the end surface 33' preventing any fluid from flowing through passages 50'. As a result, the only flow path between the chambers would be through orifice 28' which connects chamber 34' to chamber 36' through wall 18' along top portion of housing 12', as shown in FIG. 3. With this configuration, during acceleration in which the turbocharged maifold pressure lags behind the corresponding fuel flow, the fluid is forced through only the orifice 28' into chamber 36' at a schedule corresponding to that discussed above which closely corresponds to the increase in turbocharger pressure. When the pressure diminishes, a reverse flow occurs more quickly since the fluid can flow through orifice 28' and passages 50' and around check valve 27'.
As with the earlier embodiment, the rear portion of piston 30' is subjected to the atmosphere through port 46'. However, in both of these embodiments in lieu of the mainsprings 32 and 32', pressurized gas can be used in which case the chamber behind second piston 36' would be sealed to maintain the gas within the housing.
Another embodiment, as shown in FIG. 6, demonstrates a puff limiter having a feature of compactness along with other features which characterize the invention. Housing 72 of puff limiter 70, having a generally mushroom-shaped configuration, includes a head portion 74 and a stem portion 76. The head 74 is circular in configuration and has a convex outer portion 73. Extending from the center of this head toward the control rack 80 is stem 76 which defines the remaining portion of the housing 72. Housing 72 is divided into two chambers 82, 84 by partition wall 86, which is attached to housing 72 at the center of head 74.
Locating shaft 78 extends into first chamber 82 defined primarily by the stem 76 and the partition wall 86. Part of locating shaft 78 extends outside of the housing for engagement by control rack 80 in a manner similar to that described with the other embodiments discussed earlier. The portion of the locating shaft 78 extending within the first chamber is attached to a piston member 88. A helical spring 90 is located between the piston member 88 and guard member 108 attached to partition wall 86 such that the spring is in continuous engagement with the piston member 88 to bias the latter away from partition wall 86 and toward the control rack 80. Also attached between the guard member 108 and the piston member 88 is a metal bellows 92 which has one end sealingly fixed to the piston member 88 and the other end sealingly fixed to guard member 108 to define a fluid-filled chamber 89. The metal bellows 92 is completely surrounded by the spring 90 such that they are both compressed and extended during movement of the piston toward and away, respectively, from partition wall 86 during operation of the puff limiter. A second bellows 104 extends throughout the second chamber 84 and is sealingly secured to the periphery of the second chamber to divide that chamber between the partition wall 86 and the outer convex wall 73 of head 74. This forms a second fluid-filled chamber 91 between partition wall 86 and second bellows 104.
An orifice 94 is provided in partition wall 86 between chambers 89 and 91. Adjacent orifice 94 is a check valve 96 which allows flow of fluid from second chamber 91 into first chamber 89, but prevents flow in reverse direction. Thus, when hydraulic fluid is contained within the volume of the two chambers 89, 91 the flow of fluid will be restricted from first chamber 89 into second chamber 91 by orifice 94 but will flow much more rapidly from the second 91 into first chamber 89 through check valve 96 and orifice 94. These flow characteristics are similar to those described in connection with FIGS. 1, 2 and 3.
The piston 88 includes a front surface 100 to which there is sealingly secured first bellows 92 and on which spring 90 is seated. A rear surface 98 of piston 88 with the exception of the area of locating shaft 78 is exposed to the remainder of chamber 82. Air inlet 102 is provided in housing 70 to communicate the air intake manifold pressure to first chamber 82 entirely about metal bellows 92. Because the cross sectional area of piston rear surface 98 exposed to the air pressure within first chamber 82 is greater than that of the piston front surface 100, an increase in the air pressure above the pressure provided by the spring force of spring 90 will act over a larger cross sectional area to drive pistion 88 and the locating rod 78 toward the partition wall 86. This movement will continue, as in the other devices described earlier, until the air pressure and spring pressure reach an equilibrium point and locating shaft 78 is out of force contact with control rack 80 or the locating shaft has moved through a full stroke.
During movement toward the partition wall 86 the hydraulic fluid under pressure within the first metal bellows 92 will flow through the orifice 94 into second chamber 91. This of course will cause the second set of bellows 104 to expand to accommodate the increased volume of hydraulic fluid. Upon the reduction of air intake pressure, piston 88 under the action of main spring 90, will tend to revert to the fully extended position for shaft 78. As a result of the changes in pressure between the different chambers which arise from this condition, check valve 96 will open to permit hydraulic fluid in second chamber 91 to flow at a much faster rate into first chamber 89. The first bellows 92 and second bellows 104 will expand or shrink, accordingly, to their original sizes to accommodate the volumes of hydraulic fluid in their chambers 89 and 91.
Because it is desirable to have the locating shaft 78 move as quickly as possible to its fully extended position, it is advantageous to have a limit on the movement of the locating rod toward the partition wall 86 when under the action of relatively higher air intake pressures. For this purpose a stroke-limiting extension 106 is provided on front surface 100 of piston 88 to extend toward partition wall 86 such that, when the desired stroke is achieved, extension 106 will engage the guard 108 to prevent further movement. Otherwise, if the locating shaft was permitted to move through a stroke greater than needed into chamber 82, the return stroke would have to cover a greater distance and thus take longer time. The quicker locating shaft can return to a more extended position, the less likelihood that control rack 80 will move freely toward increased fuel flow during those periods when it should be engaged by the puff limiter locating rod or shaft 78.
In this particular embodiment, guard 108 surrounds orifice 94 and check valve 96 to prevent extension 106 from interfering with the operation of these elements. The length of the extension in this embodiment, can be one which allows a full stroke of about 0.3 to 0.4 inch.
The puff limiters described above are completely sealed. This insures that the desired pressures are maintained in all the chambers and leakage is kept to a minimum. In FIG. 7 there is shown a puff limiter that is refillable which allows the introduction of additional hydraulic fluid should any leakage or other reduction of fluid occur in this system. In the embodiment of FIG. 7 there is shown a refillable puff limiter 110 including a housing 112 which is generally L-shaped in configuration. The vertical portion of the "L" provides easy access to at least one of the chambers for adding hydraulic fluid as needed.
As with the other embodiments discussed above a locating shaft 114 is provided to move relative to the housing 112 depending on intake manifold air pressure and engagement of control rack 115 with locating shaft 114. An additional feature provided in this embodiment, which could also be included in the other embodiments, is an override system. For this purpose, override piston 116 is attached to locating shaft 114 for movement in override cylinder 118. A pressure inlet 120 communicates with the override cylinder 118 and is adapted to be connected to an override air pressure line in any convenient manner. In this way the action of the intake manifold pressure in moving locating shaft 114 away from the control rack 115 can by overridden by application of sufficient pressure to inlet 120 and cylinder 118 to override the control functions of the hydraulic control device.
The override feature provides an additional feature for those driving operations where it is not desirable for the locating shaft 114 to be positioned out of contact with control rack 115 regardless of the intake manifold pressure. For example, when in reverse or low forward gears it is desirable to prevent undue torque delivery from the transmission. In these gear positions the override system can be actuated to lock the locating shaft into a fully extended position and limit control rack movement and ultimately fuel flow. Such a limitation on fuel effects a corresponding limit on torque. This override feature can be included in a system to actuate and deactuate automatically depending on the gear ratio chosen by the operator.
In housing 112 there is a first chamber 122 and a second chamber 124 located in the "L" above the first chamber 122 and separated therefrom by a wall or a floor member 126. As with the other embodiments, wall 126 includes orifice 128 and check valve 130 to restrict flow of fluid from first chamber 122 into second chamber 124, but to allow reverse flow from the second chamber 124 into the first chamber 122 at an increased rate.
Except for the location of these two chambers, their operation is substantially identical to that of puff limiters described earlier; however, the piston configuration and various other elements in chamber 122 may be different. For example, the piston 132 is attached to the internal walls of the first chamber 122 by rolling diaphragm 134. The rear side 131 of piston 132 as well as rolling diaphragm 134 are in communication with the air intake pressure inlet 136 such that the application of manifold air intake pressure is transmitted directly to the rear surface of piston 132. Front surface 133 of piston 132 is engaged by main spring 138 which extends between the piston 132 and an opposite wall 135 of first chamber 122 to bias piston 132 toward control rack 115. As before, either under the action of intake manifold pressure or the application of the control rack, piston 132 can be moved into the first chamber 122 thereby forcing the liquid therein upwardly through orifice 128 into second chamber 124. Also, an extension 139 is provided extending from front surface 133 into first chamber 122 to limit the stroke of piston 132 in same manner as extension 106 of the embodiment shown in FIG. 6.
The top portion of the second chamber 124 is provided with a removable lid 140 which can be snapped in place or otherwise releasably fixed to the top of the housing in any convenient manner. As shown, lid 140 is provided with circular lip member 142 which engages recess 144 in the walls of the second chamber 124 and permit the lid to simply be snapped into place. Lid 140 includes an air vent 141 such that the hydraulic fluid within second chamber 124 is subjected to atmospheric pressure. With this configuration, should the hydraulic fluid be reduced for some reason, lid 140 can be quickly removed to facilitate access to second chamber 124. Because of the location and configuration of the second chamber, the volume of hydraulic fluid can be increased to a desired level and the lid replaced.
Another embodiment using a refillable type housing is shown in FIG. 8. Since many of the elements of FIG. 8 are essentially the same as those of FIG. 7, they will not be reiterated but are simply numbered in prime form so that the similarities can be readily appreciated. The major differences between these embodiments is the elimination of the main spring 138 and rolling diaphragm 134. These elements are replaced by a metal bellows 148' which has sufficient resiliency to act as a spring in returning the locating shaft 114' upon reduced intake manifold pressure. As with the embodiment of FIG. 7, the intake manifold pressure is applied to rear surface of the piston to move it into the first chamber and force the liquid upwardly into the second chamber.
The latter configuration of course reduces the number of elements required for operation of the puff limiter without significant loss in efficiency and operation. As a result a compact, efficient and yet more economical device can be achieved. This type of metal bellows having the needed spring force can be used with other embodiments described earlier; however, there may have to be other changes in the configuration to accommodate the metal spring bellows in lieu of the type of bellows and the main spring which have characterized the other embodiments. | A fuel controller to retard rate of increase in fuel flow during acceleration when corresponding intake pressure is not at a desirable level. Particularly in turbo-charged engines, during periods of acceleration, increase in air pressure lags behind the increased fuel flow. This results in a fuel rich mixture which produces a "puff" of exhaust smoke when combusted. The controller retards the increase in fuel flow to minimize this lag and reduce exhaust smoke which would otherwise occur. | 5 |
BACKGROUND
The invention relates to a device for detachable fastening of an embroidery frame on an embroidery frame support, and more particularly to such devices for an embroidery module in a program-controlled sewing or embroidering machine.
The connection between an embroidery frame and its support which has the drive apparatus for the embroidery frame, must be separable in order on the one hand to have the possibility of being able to fasten embroidery frames of various size and shape on the embroidery frame support, and on the other hand, to be able to lay the material to be embroidered, for example a fabric, outside the sewing machine into the embroidery frame, and to fasten it there.
From DE-GM 29 614 512, such a device for detachable fastening of an embroidery frame on the embroidery frame support of a program-controlled sewing or embroidering machine is known. In the embroidery frame support which is arranged in household sewing machines alongside the lower arm and is connected with this through coupling and latching devices, the drive means for movement of the embroidery frame attachments in the x and y direction is arranged. On the embroidery frame support, a holding angle of steel with upward-projecting retaining studs is provided for connecting or coupling the embroidery frame. On the embroidery frame, a guidance channel open downward is fastened, into which the vertical section of the holding angle is latchable with the retaining studs insertable from below, and latchable through two opposing movable locking slides. The sliding interlocks are guided lengthwise in the guidance channel and connected with two holding plates. The holding plates project beyond the guidance channel such that they can be grasped with two fingers of a hand and can be pressed against each other. Between the two locking slides, a spring is inserted which presses these apart when the spring is released, and thus pushes the outwardly directed ends under the retaining studs in the guidance channel. This known device makes it possible, in a simple manner and with the use of only one hand, to fasten the embroidery frame on the embroidery frame support or to remove it therefrom. It has, however, the disadvantage that the embroidery frame, due to the vertically operating latching in the x and y direction, cannot be held sufficiently free of play and in this way, the reproducibility of the embroidered pattern cannot be guaranteed in every case.
From DE-GM 29612102, a device for the automatic identification of the size and construction of an embroidery frame on a sewing or an embroidering machine with program-controlled embroidering device is furthermore known. This device makes it possible for the control unit of the sewing machine to recognize the embroidery frame directly connected with the embroidery frame support and therewith to utilize completely the surface available for embroidering within the embroidery frame. As a means of identification, on the embroidery frame, in the region below the guidance channel, corresponding means of identification, for example, coding prongs, are provided. The identification means are joined fast with the coupling and latching apparatus in the known device, and for this reason only allow a recognition of the respective embroidery frame which is connected fast with the latching apparatus. If there is a possibility on the embroidery frame of connecting this at various points with the embroidery frame support, then in the known manner, no identification of the fastening point can take place on the corresponding embroidery frame.
SUMMARY
The object of the present invention is to create a device for detachable fastening of an embroidery frame which not only makes it possible to join the embroidery frame with the embroidery frame support, but to lock the embroidery frame in at different places with reference to the embroidery frame support in order to be able, by successively using correspondingly larger embroidery frames, to embroider basically larger embroidering fields.
A further object is to provide, after fastening the embroidery frame on the embroidery frame support, the possibility of making the place of attachment on the respective embroidery frame type determinable by the control unit or appropriate sensors.
This object is accomplished by a device in accordance with the invention by providing a drive connected to an embroidery frame support with an embroidery frame holding plate attached thereupon. A retaining and latching element is installed on the embroidery frame with two movable sliding interlocks with spring-loaded grips. The sliding interlocks each engage with one latching hook on correspondingly constructed latching surfaces in recesses located in plates on the embroidery frame holding plate. The retaining element is mounted movable along a guide rail on the embroidery frame, and code sections and latching slots are positioned on the guide rail or on the embroidery frame.
With the device of the invention, a play-free latching of the embroidery frame on the embroidery frame support is possible, and at the same time, with one and the same latching and coupling device, the embroidery frame can not only be joined with the embroidery frame support, but also to move this without the prior detachment from the embroidery frame support, latching it again, and identifying the latching site through the control unit. By pressing together both holding buttons, the embroidery frame can consequently be lifted from the embroidery frame support again as previously, or it can be slid along a guide track fastened to the embroidery frame and fixed at a suitable position, and the fastening site on the embroidery frame can be recognized by the guide unit of the machine. Sliding the embroidery frame in relation to the embroidery frame support takes place through briefly pressing the holding buttons together and subsequent lateral sliding of the embroidery frame. The locking in into the adjacent operating position then takes place automatically. When locking in, additionally a play-free clamping of the embroidery frame with the embroidery frame support takes place without further interventions by the operator being necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in greater detail on the basis of a preferred embodiment. In the drawings:
FIG. 1 is a perspective view of a household sewing machine with an attached embroidering module and installed embroidery frame in accordance with the present invention,
FIG. 2 is a plan view on the embroidering module and the embroidery frame as well as on the front end of the lower arm of the sewing machine with the embroidery plate,
FIG. 3 is a perspective view of the latching and coupling apparatus without casing when releasing the latching on position “ 44 ,”
FIG. 4 is a perspective view of the latching and coupling apparatus without casing with a locked in jack on position “ 44 ,”
FIG. 5 is a perspective view of the latching and coupling apparatus with casing upon releasing the latching on position “ 44 .”
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The sewing machine in accordance with FIGS. 1 and 2 has the usual sewing components, operating elements and other outfitting parts (in part not indicated in greater detail). It basically includes the machine housing 1 , the free arm 3 and the base plate 5 . On the machine housing 1 , for example, a video screen 7 , a track ball 9 with dedicated activation key (OK) 11 and release key (CL) 13 and a row of keys (not indicated in greater detail) for the direct selection of special functions. The needle 17 is shown that acts through the tapping hole 15 with a not illustrated holding device, and the presser foot that operates on the (not illustrated) sewing material is designated with 19 . The basic unit 21 of a mechanical and electrical connecting device (not illustrated) with the embroidering module 23 joinable with the sewing machine 1 contains the program-controlled drive apparatus for the embroidery frame support 25 for moving the support 25 in the x direction. In the embroidery frame support 25 , further drive equipment is provided for moving the embroidery frame 27 in the y direction. The embroidery frame 27 is, as generally typical, constructed in two parts and includes a closed interior frame 27 a and a divided outer frame 27 b . On the outer frame 27 b , a clamping device 29 for clamping the sewing material is arranged. The embroidery frame 27 is connectable with the embroidery frame support 25 by means of a fastening device generally designated with 31 .
In FIGS. 3 and 4, the embroidery frame holding plate 35 is visible in the foreground, from which only the two plates 37 with the hooks 39 extending therefrom project beyond the housing of the embroidery frame support 25 (the latter omitted in FIG. 3 ). In the background, a short segment of the embroidery frame 27 with the guide and coding rail 41 attached thereupon are visible. On guide rail 41 , for example, there are three coding segments 43 , 44 , 45 , the latter being partially visible and partly covered by the embroidery frame holding plate 35 . The coding segments 43 , 44 , 45 can be made of pronged edges. It is also possible to configure these as a bar code (not shown). On the guide rail 41 , for example, a retaining and latching element, in short called retaining element 49 which forms the fastening device, is mounted movable longitudinally in a guide groove 47 . The retaining element 49 can be fixed and locked in on latching and retaining slots 51 in the region of coding segments 43 to 45 on the guide rail 41 . The retaining element 49 , which is represented with cover 57 broken away in FIGS. 3 and 4, includes a supporting body 53 which partially encloses the guide rail 41 , or extends below on its two ends. The two ends of the supporting body 53 are advantageously configured as end plates 55 , which close the cover 57 on the end faces. Between the two end plates 55 , in the middle, a longitudinal guide 59 is constructed for two sliding interlocks 61 mounted movably there. On the sliding interlocks 61 , two upwardly projecting grip plates 63 are provided, which project upwardly beyond the covering 57 . The sliding interlocks 61 include outwardly directed wedges 65 which engage oblique surfaces 67 on the retaining element 49 that are arranged basically parallel to the first wedge surface. The second wedge surfaces of the wedges 65 lie on the plates 37 , and in this way brace the embroidery frame 27 free of play on the embroidery frame support 25 . Furthermore, the sliding interlocks 61 include an outwardly directed latching hook 68 with an upward-lying oriented surface, which latching hooks 68 extend on the underside of the corresponding hooks 39 on the plates 37 in arrangement.
Between the two sliding interlocks 61 , two helical springs 69 are held in a pre-loaded condition. The outside ends of the springs 69 are held by pegs 71 formed on the sliding interlocks. The spring ends lying opposite one another lie on a spring housing 73 which accommodates a locating spring 75 which lies on a plane perpendicular to the axes of the helical springs 69 and perpendicular to the embroidery frame holding plate 35 . The locating spring 75 is braced above on the spring housing 73 and is held by a lug 77 on a one arm stop lever 79 . The stop lever 79 is pivoted with its one end on the retaining element 49 . The free end is configured as a downwardly directed hook 81 . Its geometrical shape is constructed such that the hook 81 can engage basically free of play in one of the retaining slots 51 on the guide rail 41 . The two helical springs 69 can moreover be braced in shell-like supports 83 on the upper side of the longitudinal guide 59 . The longitudinal guide 59 moreover takes over the lateral guide of the stop lever 79 and also supports the pivot bolt 85 . On one of the two sliding interlocks 61 , a lifting component is mounted in the form of a contact surface 70 which, when the sliding interlocks 61 are pressed together with the holding plate 63 reaches underneath the free end of the stop lever 79 and lifts the locating hook 81 out of slot 51 .
In FIG. 4, on the left side of the image, a portion of the cover 57 with one of the fastening screws 87 is represented. Furthermore, on the cover 57 , a downwardly open recess 89 is visible into which a guide cam 91 on the plate 37 of the embroidery frame holding plate 35 engages, and establishes its height position with respect to the retaining element 49 .
The function of latching and sliding the embroidery frame 27 will be explained below. An embroidery frame 27 with one, two, three or more embroidery surface sections and correspondingly many retaining slots 51 and coding sections 43 to 45 is pushed, after pressing together the two grip plates 63 , vertically from above on the two plates 37 on the embroidery frame holding plate 35 until the two guide cams 91 are completely inserted into the recesses 89 . Now the pressure exerted on the holding plates 63 by the fingers of the one hand can be diminished to the extent that on the one hand, the hook 81 of the lever 79 is sprung against the surface of the guide rail 41 . On the other, however, the wedges 65 do not yet lie snugly on the inclined surfaces 67 , and consequently a movement of the embroidery frame 17 in the guide groove 47 is possible. When the holding plates 63 are further released, the latching hooks 68 slide under the matching hooks 39 on plates 37 . In this way, the embroidery frame 27 is held vertically on the support 25 .
As soon as, with lateral sliding, the hook 81 reaches the region of a slot 51 on the guide rail 41 , the lever 79 pivots downwardly due to the force of the locating spring 75 and latches the embroidery frame 27 on the embroidery frame support 25 , for example, in the region of code section 44 (FIGS. 3 / 4 ). When no forces are operating on the grip plates 63 any more, the two helical springs 69 press the wedges 65 on the inclined surfaces 67 . Through the play of the retaining element 59 in the guide groove 47 , the supporting body 59 is pressed onto the two plates 37 . There is now present in the x and y direction a completely play-free connection between embroidery frame 27 and support 25 . Due to the engagement of the hook 81 in the slot 51 on coding site 44 , the coding resources, here prongs, come before a sensor element (not represented) on the support 25 which first of all, on the basis of the prongs, recognizes the size and construction of the embroidery frame 27 and moreover also the site at which the embroidery frame 27 is joined with the support 25 . The data gathered from the coding by the sensor element is communicated to the machine control unit. Subsequently, the embroidering of the of the embroidering field within embroidery frame 27 allocated to code segment 44 can take place. In order also to be able to process the adjacent embroidery field, the grip plates 63 are pressed together with two fingers of one hand until the hook 81 and the wedge 65 have left the snug arrangement and a lateral sliding of the embroidery frame 27 on the embroidery frame support 25 is possible. As soon as the hook 81 is latched on the adjacent slot 51 , the not represented sensor unit, on the basis of the structure of coding section 43 , ascertains the new position of the embroidery frame 27 and signals the control unit of the sewing machine 1 . This can now forward the stored sewing or embroidery pattern in the new embroidering field at the proper site. | A device for detachable fastening of an embroidery frame ( 27 ) with one or more embroidering fields on an embroidery frame support ( 25 ) of a program-controlled sewing or embroidering machine. On the embroidery frame ( 27 ), two sliding interlocks ( 61 ) are fastened which guarantee a play-free latching in the x and y direction and which, for sliding the embroidery frame ( 27 ) in relation to the embroidery frame support ( 25 ), move a latching element temporarily out of a latching slot ( 51 ). The latching element is configured as a pivotable lever with a downward-projecting detent. | 3 |
BACKGROUND OF THE INVENTION
Technical Field
The present invention relates to a novel sulfotransferase, and in particular relates to a heparan sulfate 6-O-sulfotransferase, which selectively transfers sulfate group to hydroxyl group at C-6 of N-sulfoglucosamine contained in heparin and heparan sulfate.
BACKGROUND ART
Heparin and heparan sulfate are polysaccharide belonging to glycosaminoglycan. Heparin and heparan sulfate have similar fundamental sugar chain backbones, both of which are generated by synthesis of a chain through 1→4 bond of N-acetylglucosamine (GlcNAc) and glucuronic acid (GlcA) followed by processing, however, the degree of processing is different between the both. Namely, although the both are charged strongly negatively, heparin contains larger amounts of N-sulfated glucosamine, 6-O-sulfated glucosamine, and 2-O-sulfated iduronic acid. Heparan sulfate and heparin are present in tissues in a form of proteoglycan in which the sugar chain covalently binds to a core protein, as in the same manner as other glycosaminoglycans.
Heparin proteoglycan has been found in secreted granules of mast cells and halophilic cells, and considered to contribute to packaging of histamine and basic protease. Heparan sulfate proteoglycan is widely distributed over extracellular matrices and cell surfaces, and known to concern various functions such as differentiation, growth and movement of cells, and anticoagulation.
By the way, basic fibroblast growth factor (bFGF) is a protein that strongly facilitates growth of an extremely wide variety of cells such as those of vascular system, connective tissue system, brain nervous system, and immune system. On the other hand, acidic fibroblast growth factor (aFGF) is a protein that is often found in nervous system such as brain and retina. Since aFGF binds to a cell surface receptor common to bFGF, the both are considered to have essentially the same acting mechanism.
It has been revealed that aFGF and bFGF strongly bind to a sugar chain moiety of heparan sulfate proteoglycan incorporated in extracellular matrices or basement membranes of tissues. Recently, it has been suggested that a heparin or heparan sulfate chain is essential for bFGF to bind to a high affinity receptor (Yayon, A. et al., Cell, 64, 841-848 (1991)); Rapraeger, A. C., Science, 252, 1705-1708 (1991)). Further, it has been suggested that the bFGF activity also requires binding of these sugar chains to the high affinity receptor itself (Kan, M. et al., Science, 259, 1918-1921 (1993); Guimond, S. et al., J. Biol. Chem., 268, 23906-23914 (1993)). The present inventors have demonstrated that a special structural domain concerning binding to bFGF is present on the chain of heparan sulfate, and that the binding of bFGF to the chain of heparan sulfate greatly affects metabolism of bFGF (Habuchi, H. et al. (1992) Biochem. J., 285, 805-813). It is known that binding of bFGF requires the presence of 2-O-sulfate group of iduronic acid residue and N-sulfated glucosamine residue on the heparan sulfate chain (Habuchi, H. et al., Biochem. J., 285, 805-813 (1992); Turnbull, J. E. et al., J. Biol. Chem., 267, 10337-10341 (1992)).
It has been reported that heparan sulfate relevant to formation of highly organized basement membrane has a high degree of sulfation at C-6 of glucosamine residue (Nakanishi, H. et al., Biochem. J., 288, 215-224 (1992)). It has been also reported that the affinity of heparin to fibronectin increases in accordance with the molecular weight and the sulfate content of heparin (Ogamo, A. et al., Biochim. Biophys. Acta, 841, 30-41 (1985)). It is also known that the higher the ability of transposition of a cell strain clone originating from Lewis-lung-carcinoma is, the more the content of 6-O-sulfation in synthesized heparan sulfate is (Nakanishi, H., Biochem. J., 288, 215-224 (1992)), and that the degree of sulfation of heparan sulfate decreases in accordance with malignant alteration. Accordingly, it is considered that sulfation plays an important role for expression of physiological activities of metastasis and heparan sulfate.
Considering the importance of sulfation in expression of physiological activities of heparin and heparan sulfate, a method for sulfating a specific site of heparin and heparan sulfate may be essential for analysis of physiological activities and modification of functions of heparin and heparan sulfate. A method for chemically introducing sulfate group selectively into N- and O-positions has been already reported (Shin-Seikagaku-Jikken-Koza (New Biochemical Experiment Course), 3, "Saccharides II", p324, published by Tokyo-Kagaku-Dojin). However, it requires complicated treatment operations, requires many kinds of reagents, and takes a long time. Thus a method for enzymatically introducing sulfate group has been demanded. A heparan sulfate (GlcN) 2-N-sulfotransferase has been isolated and purified as an enzyme for N-selectively introducing sulfate groups (Shin-Seikagaku-Jikken-Koza, 3, "Saccharides II", p194, published by Tokyo-Kagaku-Dojin). It has been also tried to isolate and purify an enzyme which transfers sulfate group selectively to C-6 of glucosamine of heparan sulfate (heparan sulfate (GlcNAc) 6-O-sulfotransferase). However, it was reported that the enzyme was contaminated with iduronic acid (IdoA) 2-O-sulfotransferase even after purification to a high degree, and the separation of the both was difficult (Wald, H. et al., Glycoconjugate J., 8, 200-201 (1991)).
Considering the importance of sulfation in expression of physiological activities of heparin and heparan sulfate, it is very important to develop a method for transferring sulfate group to heparin and heparan sulfate not only to study functional analysis of heparin and heparan sulfate but also to provide heparin and heparan sulfate for the purpose of creation of pharmaceuticals having physiological activities preferable for human. Especially, heparan sulfate (GlcN) 2-N-sulfotransferase has now been isolated, and thus isolation and purification of heparan sulfate (GlcN) 6-O-sulfotransferase have been waited for.
SUMMARY OF THE INVENTION
The present invention has been made taking the aforementioned viewpoints into consideration, an object of which is to provide a heparan sulfate 6-O-sulfotransferase which selectively introduces sulfate group into C-6 of glucosamine of heparin and heparan sulfate.
The present inventors have diligently searched for an enzyme which selectively transfers sulfate group to hydroxyl group at C-6 of N-sulfoglucosamine contained in heparin and heparan sulfate, that is heparan sulfate 6-O-sulfotransferase (hereinafter referred to as "heparan sulfate 6-sulfotransferase" or the enzyme of the present invention), succeeded in isolation and purification of the enzyme, confirmed that the enzyme selectively transfers sulfate group to hydroxyl group at C-6 of N-sulfoglucosamine of heparin and heparan sulfate, and arrived at the present invention.
Namely, the present invention lies in a heparan sulfate 6-sulfotransferase having the following physical and chemical properties:
(i) action: sulfate group is selectively transferred from a sulfate group donor to hydroxyl group at C-6 of N-sulfoglucosamine residue;
(ii) substrate specificity: sulfate group is transferred to heparan sulfate or CDSNS-heparin completely desulfated and N-resulfated heparin, but sulfate group is not transferred to chondroitin and chondroitin-4-sulfate;
(iii) optimum reaction pH: pH 6-7;
(iv) optimum ionic strength: 0.1-0.3M (in the case of sodium chloride); and
(v) inhibition and activation: the enzyme is inhibited by dithiothreitol and adenosine-3',5'-diphosphate, and activated by protamine.
The present invention also provides a method of producing heparan sulfate 6-O-sulfotransferase, comprising the steps of cultivating cell lines selected from fibroblast cells originating from ovary tissue of Chinese hamster, cells originating from mouse breast carcinoma, and cells originating from human osteosarcoma in an appropriate medium in which the cells can grow, secreting and accumulating the aforementioned heparan sulfate 6-O-sulfotransferase in the medium, and collecting the heparan sulfate 6-O-sulfotransferase from the medium.
The enzyme of the present invention is conveniently referred to as "heparan sulfate 6-O-sulfotransferase" or "heparan sulfate 6-sulfotransferase". However, it is not meant that the substrate of the enzyme is limited to heparan sulfate. The enzyme has an activity to transfer sulfate group also on CDSNS-heparin. Unmodified heparin usually has sulfate groups at C-6 of almost all glucosamine residues. However, there exists heparin having hydroxyl groups at C-6 of a few glucosamine residues. The enzyme of the present invention also transfers sulfate group to C-6 of glucosamine residue of such heparin. Therefore, in this specification, ordinary heparin as well as modified heparin having sulfate group at C-2 and hydroxyl group at C-6 of glucosamine residue is occasionally referred to simply as "heparin".
<1> Heparan sulfate 6-sulfotransferase of the present invention
The enzyme of the present invention is an enzyme which has been isolated for the first time according to the present invention, and has the following physical and chemical properties.
(i) Action
Heparan sulfate or heparin having sulfate group at C-2 and hydroxyl group at C-6 of glucosamine residue is used as an acceptor. Sulfate group is selectively transferred from a sulfate group donor to hydroxyl group at C-6 of N-sulfoglucosamine residue thereof, while it is scarcely transferred to uronic acid residue. The sulfate group donor is preferably exemplified by active sulfate (3'-phosphoadenosine 5'-phosphosulfate; hereinafter referred to as "PAPS").
(ii) Substrate specificity
Sulfate group is transferred to heparan sulfate or CDSNS-heparin, but sulfate group is not transferred to chondroitin and chondroitin-4-sulfate. Sulfate group is scarcely transferred to heparin or heparan sulfate having no sulfate group at C-2 of glucosamine such as NDS-heparin (N-desulfated heparin). Therefore, it may be necessary for the sulfate group acceptor for the enzyme of the present invention that C-2 of glucosamine residue of mucopolysaccharide is sulfated.
(iii) Optimum reaction pH
The enzyme of the present invention has a high activity to transfer sulfate group in a range of pH 6-7, especially in the vicinity of pH 6.3. Little activity is provided at pH 4.7 or below.
(iv) Optimum ionic strength
The activity of the enzyme of the present invention increases as the ionic strength increases. In the case of NaCl, the highest activity is presented at 0.1-0.3M, especially in the vicinity of 0.15M. The activity gradually decreases when the concentration of NaCl increases exceeding the aforementioned range. The activity becomes extremely low at 0.5M.
(v) Inhibition and activation
The activity of the enzyme of the present invention is inhibited by dithiothreitol (DTT) and adenosine-3',5'-diphosphate (3',5'-ADP), and activated by protamine. The activity is reduced to a half in the presence of 1 mM DTT. The activity increases about 10-fold in the presence of protamine of more than about 0.025 mg/ml as compared with the activity in the absence of protamine.
(vi) Michaelis constant
The enzyme of the present invention has a Michaelis constant (Km) of 4.4×10 -7 M for PAPS when heparan sulfate is used as a sulfate group acceptor and PAPS is used as a donor.
(vii) Other properties
As a result of analysis of an active fraction of the enzyme of the present invention obtained from a culture liquid of CHO cell by means of SDS-polyacrylamide gel electrophoresis, bands having molecular weights of 45 kDa and 52 kDa have been found. Results of determination of amino acid sequences at N-terminals of these proteins are shown in SEQ ID NOS. 1 and 2, respectively. As a result, it has been found that the N-terminal sequences of these proteins are extremely similar, suggesting that they are correlated. However, it is not clarified which of these proteins is the enzyme of the present invention, or whether or not the both are the enzyme of the present invention. In any case, the physical and chemical properties of the enzyme of the present invention described above have been determined by using the fraction containing the both proteins of 45 kDa and 52 kDa. The mobility of the both proteins on electrophoresis was not affected by the presence of mercaptoethanol.
As a result of analysis of the enzyme of the present invention after an N-glycanase (produced by Genzyme Co.) treatment by means of SDS-polyacrylamide gel electrophoresis, the aforementioned bands of 45 kDa and 52 kDa have disappeared, while bands of 38 kDa and 43 kDa have newly appeared. According to this fact, it is suggested that these proteins are glycoproteins containing more than 15% of sugar.
The activity to transfer sulfate group of the enzyme of the present invention can be measured by using 35 S!-PAPS as a sulfate group donor and heparin or heparan sulfate as a sulfate group acceptor, allowing the enzyme of the present invention to act on them, and counting radioactivity of 35 S! incorporated into heparin or heparan sulfate. In this measurement, it is preferable that pH of a reaction solution is 6-7, the ionic strength is about 0.15M, and protamine is added in an amount more than 0.025 mg/ml. Specifically, for example, a reaction solution (50 μl) containing 2.5 μmol of imidazole hydrochloride (pH 6.8), 3.75 μg of protamine hydrochloride, 25 nmol of CDSNS-heparin (completely desulfated and N-resulfated heparin: heparin obtained by desulfation of N,O-sulfate groups followed by N-resulfation), 50 pmol of 35 S!-PAPS (about 5×10 5 cpm), and the enzyme is kept at a temperature of 37° C. for 20 minutes, followed by heating at 100° C. for 1 minute to stop the reaction. Subsequently, 0.1 μmol of chondroitin sulfate A is added as a carrier, and then 35 S-glycosaminoglycan is precipitated by adding cold ethanol containing 1.3% potassium acetate in an amount three times the reaction solution. Further, 35 S!-PAPS and its degradation products are removed by desalting, liquid scintillator is added, and radioactivity of 35 S! is measured by using a liquid scintillation counter. In the present invention, an activity to transfer 1 pmol of sulfate group per 1 minute under the aforementioned condition is defined as an enzyme amount of 1 unit (U).
<2> Production method of the enzyme of the present invention
The enzyme of the present invention having the properties described above is obtained by cultivating cell line such as cell line originating from animals, for example, fibroblast cell originating from ovary tissue of Chinese hamster, cell originating from mouse breast carcinoma, or cell originating from human osteosarcoma, specifically CHO cell (for example, ATCC CCL61 and the like), FM3A cell (JCRB0701 from JCRB Cell Bank of National Institute of Hygienic Sciences and the like), or MG63 cell (for example, ATCC CRL1427 and the like) in an appropriate medium in which the cells can grow, secreting and accumulating the enzyme in the medium, and collecting it from the medium. Among the cell lines described above, CHO cell is preferable from a viewpoint of yield of the enzyme of the present invention. The enzyme of the present invention may be obtained from cultured cells other than those described above, however, the cell lines described above are preferred because of good growth properties and possibility of cultivation in a serum-free medium. The enzyme of the present invention can be also extracted from cultured cells themselves. The enzyme of the present invention may be used as a crude enzyme when other contaminating sulfotransferase activities can be effectively suppressed.
The medium to be used for the cultivation of the cell lines described above is not specifically limited, however, it is preferable to use a serum-free medium. If the cultivation in a serum-free medium is possible, the protein concentration in the medium can be made extremely low, which makes it easy to purify the enzyme of the present invention from the medium. A commercially available serum-free medium such as Cosmedium-001 medium (Cosmo Bio) may be used as the serum-free medium.
When the aforementioned CHO cell or the like are cultivated, they may be proliferated to a required number of cells by using Dulbecco's Modified Eagle Medium or the like, and the medium may be changed to the serum-free medium to continue cultivation.
In the present invention, for example, it is preferable that the cell lines are cultivated for more than 10 days while exchanging the medium every second day, and used media are combined to collect the enzyme of the present invention. Therefore, in order to prevent cells from peeling off from a cultivation vessel such as a dish during the exchange of the medium, it is preferable to add ascorbic acid in an amount of about 50 μg/ml to enhance synthesis and deposition of collagen as a cell-adhesion substance. In order to avoid growth of microorganisms, it is preferable to add antibiotics such as penicillin and streptomycin to the medium. When the medium as described above is used to conduct cultivation in the same manner as ordinary cultured cells by using roller bottles or dishes, the enzyme of the present invention is secreted into the medium.
The enzyme of the present invention can be purified from the medium by means of affinity chromatography using a Heparin-Sepharose CL-6B (produced by Pharmacia) column, a 3',5'-ADP-agarose column and the like, or Resource Q (produced by Pharmacia) column chromatography. Especially, 3',5'-ADP-agarose column chromatography is effective. Additionally, the enzyme can be purified by using known enzyme purification methods such as ion exchange chromatography, gel filtration, electrophoresis, and salting out, if necessary.
The enzyme of the present invention may be also obtained by using transformed cells obtained by isolating a gene coding for the enzyme of the present invention from the cultured cells described above, and introducing it into other cultured cells or microbial cells.
The enzyme of the present invention has enabled enzymatic selective introduction of sulfate group into C-6 of N-sulfoglucosamine contained in heparin and heparan sulfate. The heparan sulfate 6-sulfotransferase selectively introduces sulfate group into C-6 of N-sulfoglucosamine of heparin and heparan sulfate extremely strictly. Accordingly, it is expected to exploit the enzyme for reagents useful for studies such as functional analysis of heparin and heparan sulfate.
Considering creation of heparin and heparan sulfate having new physiological activities unknown at present and application as pharmaceuticals by using the enzyme of the present invention, it can be expected to create heparin or heparan sulfate having physiological activities preferable for human. Since it is known that the degree of sulfation of heparan sulfate decreases in accordance with malignant alteration, it is also expected to enable the amount of the enzyme to be related to malignant alteration by producing an antibody against the enzyme of the present invention and detecting the enzyme of the present invention in tissues.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows HPLC chromatograms of heparitinase digests of products of the reaction to transfer sulfate group to CDSNS-heparin by heparan sulfate O-sulfotransferase secreted by CHO cell (A) and FM3A cell (B).
FIG. 2 shows a result of 3',5'-ADP-agarose chromatography for the enzyme of the present invention, wherein closed circles indicate heparan sulfate 6-sulfotransferase activity, open circles indicate protein concentration, and a broken line indicates 3',5'-ADP concentration.
FIG. 3 shows a result of second Heparin-Sepharose CL-6B chromatography for the enzyme of the present invention, wherein closed circles indicate heparan sulfate 6-sulfotransferase activity, open circles indicate chondroitin sulfotransferase activity, and a broken line indicates NaCl concentration.
FIG. 4 shows a result of SDS-polyacrylamide gel electrophoresis for fractions fractionated by second Heparin-Sepharose CL-6B chromatography, wherein numbers at the top of the figure indicate fraction numbers.
FIG. 5 shows a result of SDS-polyacrylamide gel electrophoresis for enzyme fractions of the present invention in each of purification steps and purified enzyme treated with 5% mercaptoethanol, wherein lane 1 is buffered culture liquid components, lane 2 is an absorbed fraction of first Heparin-Sepharose CL-6B, lane 3 is an absorbed fraction of 3',5'-ADP-agarose, lane 4 is fractions of a portion of a horizontal line (thick line) shown in FIG. 3 in second Heparin-Sepharose CL-6B chromatography, and lane 5 is the same fractions as those in lane 4 but reduced with 5% mercaptoethanol.
FIG. 6 shows a result of SDS-polyacrylamide gel electrophoresis of the enzyme of the present invention treated with or without N-glycanase (produced by Genzyme Co.), wherein lane 1 is the enzyme of the present invention with no treatment, lane 2 is the enzyme of the present invention treated with N-glycanase, and lane 3 is N-glycanase.
FIG. 7 shows HPLC chromatograms of heparitinase digests of products of the reaction to transfer sulfate group to CDSNS-heparin (A) and heparan sulfate (B) by the enzyme of the present invention.
FIG. 8 shows pH-enzyme activity curves demonstrating optimum pH of the enzyme of the present invention, wherein open circles indicate Tris-HCl buffer, closed circles indicate imidazole-HCl buffer, open squares indicate MES buffer, and closed squares indicate potassium acetate buffer.
FIG. 9 shows a DTT concentration-enzyme activity curve showing the influence of DTT on the enzyme of the present invention.
FIG. 10 shows a protamine concentration-enzyme activity curve showing the influence of protamine on the enzyme of the present invention.
FIG. 11 shows an NaCl concentration-enzyme activity curve showing optimum NaCl concentration of the enzyme of the present invention, wherein closed circles indicate no addition of DTT, and open circles indicate addition of 2 mM DTT.
FIG. 12 shows a Lineweaver-Burk plot for calculating Km of the enzyme of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below.
<1> Reagents and measurement of enzyme activity of heparan sulfate 6-sulfotransferase
(1) Reagents
Available sources and methods for obtaining reagents and samples used in this embodiment are described below.
35 S!-H 2 SO 4 was purchased from Japan Radioisotope Association. Dulbecco's Modified Eagle Medium, trypsin (type III from bovine spleen), PAPS, 3',5'-ADP-agarose, and heparin were purchased from Sigma. Cosmedium-001 medium was purchased from Cosmo Bio. Fast desalting column, and Heparin-Sepharose CL-6B column were purchased from Pharmacia-LKB. PAMN column (silica column with bound polyamine) was purchased from YMC. Chondroitinase ABC, heparitinase I, II, III, chondroitin sulfate A (from shark cartilage, 4S/6S:80/20), CDSNS-heparin (completely desulfated and N-resulfated heparin: heparin obtained by desulfation of N,O-sulfate groups followed by N-resulfation), and unsaturated disaccharide kit from glycosaminoglycan were purchased from Seikagaku Corporation. 35 S!-PAPS was prepared in accordance with a method described by Delfert, D. M. and Conrad, E. H. (1985) in Anal. Biochem., 148, 303-310. Chondroitin (from squid skin) was prepared in accordance with a method described by Habuchi, O. and Miyata, K. (1980) in Biochim. Biophys. Acta, 616, 208-217.
(2) Measurement of heparan sulfate 6-sulfotransferase
The enzyme activity was measured in accordance with a method described below in purification steps of the heparan sulfate 6-sulfotransferase, analysis of properties of the enzyme and so on.
An enzyme reaction solution was 50 μl which contained 2.5 μmol of imidazole hydrochloride (pH 6.8), 3.75 μg of protamine hydrochloride, 25 nmol of CDSNS-heparin, 50 pmol of 35 S!-PAPS (about 5×10 5 cpm), and the enzyme. This reaction solution was kept at a temperature of 37° C. for 20 minutes, followed by heating at 100° C. for 1 minute to stop the reaction. Subsequently, 0.1 μmol of chondroitin sulfate A was added as a carrier, and then 35 S -glycosaminoglycan was precipitated by adding cold ethanol containing 1.3% potassium acetate in an amount three times the reaction solution. Further, 35 S!-PAPS and its decomposed products were completely separated by using a fast desalting column as described before (Habuchi, O. et al., (1993) J. Biol. Chem., 268, 21968-21974). Liquid scintillator (Ready Safe Scintillator, produced by Beckman) was mixed therewith, and radioactivity was measured by using a liquid scintillation counter to calculate the amount of transferred sulfate group. An activity to transfer 1 pmol of sulfate group per 1 minute under the aforementioned condition was defined as an enzyme amount of 1 unit (U).
The activity of chondroitin sulfotransferase was also measured in the same manner.
(3) Measurement of contents of galactosamine and glucosamine of glycosaminoglycan
Contents of galactosamine and glucosamine of glycosaminoglycan were measured by an Elson-Morgan method after hydrolyzing the glycosaminoglycan in 6M HCl at 100° C. for 4 hours.
<2> Analysis of heparan sulfate O-sulfotransferase secreted by various cultured cells CHO cell (ATCC CCL61), FM3A cell (JCRB 0701), and MG63 cell (ATCC CRL1427) were inoculated at a density of 3×10 6 cells/dish respectively, and cultivated for 2 days in 10 ml of Dulbecco's Modified Eagle Medium containing 10% fetal bovine serum, 10 mM HEPES (N-2-hydroxyethylpiperazine-N'-2-ethanesulfonic acid), pH 7.2, 50 units/ml of penicillin, and 50 μg/ml of streptomycin. Subsequently, cells were cultivated for 48 hours by using 10 ml of Cosmedium-001 medium containing 50 μg/ml of ascorbic acid and 10 mM HEPES, pH 7.2. Each of the media was applied to a Heparin-Sepharose column (1 ml) equilibrated with buffer A (10 mM Tris-HCl, pH 7.2, 10 mM MgCl 2 , 2 mM CaCl 2 , 20% glycerol, 0.1% Triton X-100) containing 0.15M NaCl, washed with buffer A containing 0.15M NaCl, and eluted with buffer A containing 1.0M NaCl. The eluted fraction was used as a crude enzyme of heparan sulfate O-sulfotransferase to make measurement using CDSNS-heparin as an acceptor. The heparan sulfate O-sulfotransferase activity per 2×10 7 cells of each of the cells is shown in Table 1. As a result, a culture liquid of the CHO cell presented the highest sulfotransferase activity.
TABLE 1______________________________________ Heparan sulfateCultured cells O-sulfotransferase activity______________________________________CHO 7.74FM3A 1.25MG63 1.31______________________________________
A reaction product, which was obtained by maintaining a reaction solution containing CDSNS-heparin, 35 S!-PAPS and the crude enzyme at a certain temperature, was digested with a mixed solution containing heparitinase I, II, III shown below at 37° C. for 2 hours (50 μl containing 25 nmol or less of reaction product, 50 mM Tris-HCl (pH 7.2), 1 mM CaCl 2 , 2 μg bovine serum albumin (BSA), 5 mU heparitinase I, 0.5 mU heparitinase II, 5 mU heparitinase III).
The digest was separated together with standard unsaturated disaccharides using HPLC (high speed liquid chromatography, column: silica column with bound polyamine (PAMN column)) in accordance with a known method (Habuchi, H. et al., (1992) Biochem. J., 285, 805-813), fractionated into each aliquot of 0.6 ml, and mixed with 3 ml of liquid scintillator (Ready Safe Scintillator, produced by Beckman) to measure radioactivity by using a liquid scintillation counter. Heparitinase is an enzyme which cuts α-N-acetyl/-sulfo-D-glucosaminyl (1→4) uronic acid bond of heparan sulfate in a manner of an elimination reaction to produce oligosaccharides having Δ 4 -hexuronic acid at non-reducing end.
Results are shown in FIG. 1 (A: CHO cell, B: FM3A cell). In FIG. 1, reference numerals 1-5 indicate unsaturated disaccharide residues shown below (see formula 1 and Table 2). "ΔDiHS" indicates unsaturated disaccharide produced by degradation of heparin by heparitinase. "6,N" indicates a position of sulfation of glucosamine. "U" indicates the fact that C-2 of uronic acid is sulfated.
1: ΔDiHS-6S
2: ΔDiHS-NS
3: ΔDiHS-di(6,N)S
4: ΔDiHS-di(U,N)S
5: ΔDiHS-tri(U,6,N)S ##STR1##
TABLE 2______________________________________Unsaturated disaccharideresidue R.sup.1 R.sup.2 R.sup.3______________________________________ΔDiHS-6S SO.sub.3.sup.-- Ac HΔDiHS-NS H SO.sub.3.sup.-- HΔDiHS-di(6,N)S SO.sub.3.sup.-- SO.sub.3.sup.-- HΔDiHS-di(U,N)S H SO.sub.3.sup.-- SO.sub.3.sup.--ΔDiHS-tri(U,6,N)S SO.sub.3.sup.-- SO.sub.3.sup.-- SO.sub.3.sup.--______________________________________
As clarified from FIG. 1, the unsaturated disaccharide components produced by heparitinase digestion of CDSNS-heparin having sulfate group transferred from 35 S!-PAPS dominantly included ΔDiHS-di(6,N)S, however, ΔDiHS-di(U,N)S was contained in a trace amount. According to the result, it has been clarified that most of the heparan sulfate sulfotransferase activity produced and secreted by CHO cell is the heparan sulfate 6-sulfotransferase activity, scarcely containing the iduronic acid 2-sulfotransferase activity.
<3> Purification of heparan sulfate 6-sulfotransferase produced by CHO cell
(1) Cultivation of CHO cell and preparation of culture liquid fractions
CHO cell (ATCC CCL61) were inoculated in a roller bottle (produced by In vitro Science Product INC.) at a density of 3.3×10 7 cells/bottle, and cultivated for 2 days in 100 ml of Dulbecco's Modified Eagle Medium containing 10% fetal bovine serum, 10 mM HEPES, pH 7.2, 50 units/ml of penicillin, and 50 μg/ml of streptomycin. Subsequently, using 100 ml of Cosmedium-001 medium containing 50 μg/ml of ascorbic acid and 10 mM HEPES, pH 7.2, the culture liquid was recovered every second day, and a fresh medium was added to continue cultivation.
The cultivation was continued for 10 days. The recovered culture liquid was collected, and centrifuged at 1000×g for 5 minutes to remove floating cells. MgCl 2 , CaCl 2 , Tris-HCl, pH 7.2, glycerol, and Triton X-100 were added to the supernatant to give 10 mM, 2 mM, 10 mM, 20%, and 0.1% respectively to provide a buffered culture liquid, and it was stored at -20° C. until purification of the enzyme was started.
(2) Purification of heparan sulfate 6-sulfotransferase
All of the following operations were performed at 4° C.
(i) First step: first Heparin-Sepharose CL-6B chromatography
The buffered culture liquid (16 L) prepared as described above was applied to a Heparin-Sepharose CL-6B column (20×65 mm, 20 ml) equilibrated with buffer A (10 mM Tris-HCl, pH 7.2, 10 mM MgCl 2 , 2 mM CaCl 2 , 20% glycerol, 0.1% Triton X-100) containing 0.15M NaCl after dividing it into 10 aliquots. The flow rate was 70 ml/hour. A fraction not absorbed to the column was washed with buffer A containing 0.25M NaCl in an amount ten times the column volume, and then an absorbed fraction was eluted with buffer A containing 1M NaCl in an amount five times the column volume. The same operation was repeated ten times. Each of eluates were combined, and introduced into a dialysis tube to which powder of polyethylene glycol #20,000 was sprinkled to be left at 4° C., and thus it was concentrated to 100 ml. This concentrated solution was exhaustively dialyzed against buffer A containing 0.05M NaCl.
Owing to the operation described above, the heparan sulfate 6-sulfotransferase activity increased about 1.6-fold. This may be caused by elimination of degradation enzymes for PAPS and inhibiting substances for heparan sulfate 6-sulfotransferase activity through the column chromatography.
(ii) Second step: 3',5'-ADP-agarose chromatography
The dialyzed solution obtained in the first step described above was applied to a 3',5'-ADP-agarose column (14×90 mm, 15 ml) equilibrated with buffer A containing 0.05M NaCl after dividing it into 2 aliquots. The flow rate was 13 ml/hour. A fraction not absorbed to the column was washed with buffer A containing 0.05M NaCl in an amount eight times the column volume, and then an absorbed fraction was eluted with a linear concentration gradient for the 3',5'-ADP concentration increasing from 0 to 0.2 mM in buffer A containing 0.05M NaCl (total volume: 150 ml). It was found that the heparan sulfate 6-sulfotransferase was unstable in 0.05M NaCl, and hence buffer A containing 1M NaCl was added beforehand to test tubes for collecting each of fractions so that the final concentration of NaCl became 0.15M.
The protein concentration and the heparan sulfate 6-sulfotransferase activity of each of eluted fractions were measured. The protein concentration was measured with a BCA kit (Pierce) using BSA (bovine serum albumin) as a standard. A result is shown in FIG. 2. Active fractions (portion shown by a thick line in FIG. 2) were collected. A part of the eluted solution was applied to a small Heparin-Sepharose column, washed with buffer A containing 0.25M NaCl, and then eluted with buffer A containing 1.0M NaCl. The activity of this fraction was measured to determine a total activity of the enzyme purified in this step.
Owing to the operation described above, the specific activity of heparan sulfate 6-sulfotransferase became 35-fold at a stroke, revealing that the operation was an extremely effective method for purification of this enzyme.
(iii) Third step: second Heparin-Sepharose CL-6B chromatography
The active fraction of the heparan sulfate 6-sulfotransferase obtained in the second step was applied to a Heparin-Sepharose CL-6B column (16×35 mm, 5 ml) equilibrated with buffer A containing 0.15M NaCl. The column was washed with buffer A containing 0.25M NaCl in an amount five times the column volume, and then an absorbed fraction was eluted with a linear concentration gradient of the NaCl concentration increasing from 0.25M to 1.2M in the buffer (total volume: 150 ml). The protein concentration, the heparan sulfate 6-sulfotransferase activity, and the chondroitin sulfotransferase activity of each of eluted fractions were measured.
A result is shown in FIG. 3. Chondroitin sulfotransferase was eluted at a salt concentration lower than that of heparan sulfate 6-sulfotransferase, and it was eliminated in this step. The chondroitin sulfotransferase transferred sulfate group to C-4 of N-acetylgalactosamine in chondroitin or chondroitin sulfate, but it did not transfer sulfate group to C-6 of N-acetylgalactosamine.
Among the fractions containing the heparan sulfate 6-sulfotransferase activity obtained as described above, fractions shown by a thick line in FIG. 3 were collected, and dialyzed against buffer A containing 0.15 M NaCl. The purified enzyme thus obtained was stored at -20° C.
As described above, the heparan sulfate 6-sulfotransferase was purified about 10,700-fold from the buffered culture liquid, and it gave approximately homogeneous two bands on SDS-PAGE as described below (FIG. 4). The degree of purification in each of the steps is shown in Table 3.
TABLE 3______________________________________ Purifi- Total Total Specific cationPurification Volume activity × protein activity × degree- Yieldstep ml 10.sup.3 U mg 10.sup.4 U/mg fold (%)______________________________________buffered 16,000 5.99 718 0.000834 1 100culture liq.1st Heparin- 1,000 9.78 76 0.0129 16 163Sepharose3',5'-ADP- 140 5.40 1.25 0.433 519 90agarose2nd Heparin- 35 2.38 0.027 8.94 10,700 40Sepharose______________________________________
(3) Analysis of purified enzyme by SDS-polyacrylamide gel electrophoresis
The purified enzyme of heparan sulfate 6-sulfotransferase and samples in each of the steps of purification obtained as described above were analyzed by SDS-polyacrylamide gel electrophoresis by using 10% gel in accordance with Laemmli (Laemmli, U. K. (1970) Nature, 227, 680-685). Bands of proteins were detected by silver staining or Coomassie Brilliant Blue staining. A result is shown in FIG. 5. Two bands of 52 kDa and 45 kDa were dominantly observed by silver staining in the second Heparin-Sepharose fraction. This fraction was reduced with 5% mercaptoethanol, and stained with Coomassie Brilliant Blue, which is shown in lane 5 in FIG. 5. No change in molecular weight of the two bands was observed between those before and after the reduction.
Next, it was investigated whether or not the sugar chain was present in the heparan sulfate 6-sulfotransferase protein. The enzyme protein was precipitated by adding TCA (trichloroacetic acid) to a heparan sulfate 6-sulfotransferase solution containing 0.15 μg of the protein so that the final concentration was 10%. The precipitate was recovered by centrifugation. The precipitate was washed with acetone and dried, and then kept at a temperature of 37° C. for 16 hours in a reaction solution described below.
The reaction solution contained 0.05M Tris-HCl, pH 7.8 containing 0.5% SDS (10 μl); 7.5% (w/v) Nonidet P-40 (5 μl); 0.25M EDTA (1.2 μl); phenylmethylsulfonylfluoride (0.3 μl); and 0.5 unit of N-glycanase (recombinant N-glycanase: produced by Genzyme).
As a result of analysis of the reaction solution described above by means of SDS-PAGE, the protein bands of 52 kDa and 45 kDa disappeared, and protein bands of 43 kDa and 38 kDa appeared (FIG. 6). This result demonstrates that the proteins of the both bands are glycoproteins containing more than 15% of sugar.
(4) N-terminal amino acid analysis of heparan sulfate 6-sulfotransferase
In order to determine amino acid sequences at N-terminals of the purified heparan sulfate 6-sulfotransferase, the proteins were transferred from the gel to a PVDF (polyvinylidene difluoride) membrane (Applied Biosystems) by electroblot at 40 V for 16 hours in 10 mM CAPS (cyclohexylaminopropanesulfonic acid) buffer (10 mM CAPS containing 10% methanol, pH 11). Amino acid sequences of samples of the enzyme proteins blotted to the PVDF membrane were determined by using a gas phase sequencer.
As a result, a sequence of 16 residues at the N-terminal was clarified for the protein of 45 kDa, demonstrating that it was a region rich in proline. This fact well coincides with the knowledge that a stem domain of sugar transferase of Golgi body is generally rich in proline. On the other hand, the band of 52 kDa had a sequence coincided with the sequence of 45 kDa except for 3 residues which could not be identified among 11 residues. Thus the two bands are considered to be proteins extremely relevant to one another.
The amino acid sequences at the N-terminals of the proteins of 45 kDa and 52 kDa are shown in SEQ ID NOS. 1 and 2, respectively. In SEQ ID NO. 1, it is extremely probable that 6th amino acid is Leu or Ala, 11th amino acid is Pro or Ala, and 14th amino acid is Arg or Phe. Although 9th, 12th, 13th, 15th and 16th amino acids are uncertain, amino acid having high possibility are shown. Also in SEQ ID NO. 2, although 2th, 6th, and 9th to 11th amino acids are uncertain, amino acid having high possibility are shown.
(5) Substrate specificity of heparan sulfate 6-sulfotransferase
In order to investigate the substrate specificity of the heparan sulfate 6-sulfotransferase of the present invention, the activity to transfer 35 S-sulfate group from 35 S!-PAPS was measured by using the crude enzyme or the purified enzyme using various substrates (25 nmol) as acceptors. Results are shown in Table 4. Numbers in parentheses in the table indicate the activity to transfer sulfate group with respect to each of the acceptors when the activity to transfer sulfate group using CDSNS-heparin as the acceptor is regarded to be 100.
TABLE 4______________________________________ Crude enzyme Purified enzymeSubstrate activity, U/ml activity, U/ml______________________________________CDSNS-heparin 11.2 (100) 74.2 (100)heparan sulfate 3.46 ( 31) 26.0 ( 35)chondroitin 1.42 ( 13) 0chondroitin-4-sulfate 0.08 (0.7) 0NDS-heparin 0.72 (6.0) 1.7 (2.3)______________________________________
The heparan sulfate 6-sulfotransferase of the present invention transferred sulfate group to CDSNS-heparin and heparan sulfate (originating from swine aorta), and transferred sulfate group to NDS-heparin (N-desulfated heparin) a little. However, no transfer was observed in chondroitin and chondroitin-4-sulfate.
In order to investigate the position of sulfate group transferred by the heparan sulfate 6-sulfotransferase of the present invention using CDSNS-heparin and heparan sulfate as acceptors and using 35 S!-PAPS as a sulfate group donor, transfer reaction products were digested with heparitinase in the same manner as described above, and analyzed by HPLC using a PAMN column. Results are shown in FIG. 7. Reference numerals in the figure are the same as those in FIG. 1.
As a result, when CDSNS-heparin was used as an acceptor, almost all of the radioactivity coincided with the elution position of standard ΔDiHS-di(6,N)S, however, a little amount of radioactivity was also present at the position of ΔDiHS-tri(U,6,N)S (FIG. 7A). On the other hand, when heparan sulfate was used as an acceptor, the radioactivity was present in approximately equal amounts at the positions of ΔDiHS-di(6,N)S and ΔDiHS-tri(U,6,N)S (FIG. 7B). When heparan sulfate was used as an acceptor, the content of the peak 5 is high as compared with the case of CDSNS-heparin. This may be caused by the fact that the content of units having sulfate group at C-2 of uronic acid in heparan sulfate used for the reaction is higher than that of CDSNS-heparin.
These results demonstrate that the heparan sulfate 6-sulfotransferase of the present invention has the activity to transfer sulfate group to C-6 of N-sulfoglucosamine existing in glycosaminoglycan, the acceptor of sulfate group probably serving well even when adjacent hexuronic acid is sulfated or not sulfated.
(6) Other enzymatic properties of heparan sulfate 6-sulfotransferase
(i) Optimum pH
Optimum pH of the enzyme of the present invention was measured. Buffers that were 50 mM Tris-HCl, 50 mM imidazole-HCl, 50 mM MES (2-(N-morpholino)ethanesulfonic acid, produced by nacalai tesque), and 50 mM potassium acetate buffer were used. The enzyme activity was measured at various pH's. Relative activities with respect to an activity in imidazole-HCl buffer (pH 6.3) are respectively shown in FIG. 8. As a result, a maximum activity was obtained at about pH 6.3.
(ii) Inhibition and activation of the enzyme of the present invention
In order to investigate the influence of dithiothreitol (DTT) and protamine on the activity of the enzyme of the present invention, DTT or protamine was added to a reaction solution at various concentrations to measure the enzyme activity. The relative activity with respect to the activity without addition of DTT is shown in FIG. 9. DTT inhibited the enzyme activity as the concentration increases. The enzyme activity decreased to 42% at 2 mM DTT and to 19% at 10 mM DTT.
The influence of protamine on the enzyme activity of the enzyme of the present invention was investigated. The relative activity with respect to the maximum activity is shown in FIG. 10. The heparan sulfate 6-sulfotransferase was remarkably activated by protamine in the same manner as chondroitin 4-sulfotransferase and chondroitin 6-sulfotransferase.
Next, the influence of NaCl on the enzyme activity was investigated. NaCl was added to an enzyme reaction solution at various concentrations in the presence or absence of DTT. Results are shown in FIG. 11. The maximum activity was observed at about 150 mM NaCl without addition of DTT, and at about 100 mM NaCl with addition of 2 mM DTT. This property is different from that of N-sulfotransferase in which the activity is inhibited depending on the concentration of NaCl.
As a result of investigation of the influence of 3',5'-ADP on the enzyme activity of the enzyme of the present invention, a strong inhibiting action was found in the same manner as other sulfotransferases.
(iii) Measurement of Michaelis constant
Michaelis constant (Km) was determined for the enzyme of the present invention when heparan sulfate was used as a sulfate group acceptor and PAPS was used as a donor. PAPS (0.125-5 μM) was added to 50 μl of a reaction solution containing 0.19 unit of the enzyme and 25 nmol of CDSNS-heparin as hexosamine, and reacted at 37° C. for 20 minutes to measure initial velocities of the reaction. A Lineweaver-Burk plot was prepared (see FIG. 12), and Michaelis constant was calculated. As a result, Km of the enzyme of the present invention for PAPS was 4.4×10 -7 M.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 2(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 16 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(v) FRAGMENT TYPE: N-terminal(vi) ORIGINAL SOURCE:(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:LeuProGlyProArgXaaProLeuGlyAlaXaaLeuLeuXaaAlaPro151015(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 11 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(v) FRAGMENT TYPE: N-terminal(vi) ORIGINAL SOURCE:(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:XaaProGlyProXaaLeuXaaLeuGlyAlaPro1510__________________________________________________________________________ | The present invention provides a heparan sulfate 6-O-sulfotransferase for selectively introducing sulfate group into hydroxyl group at C-6 of glucosamine of heparin and heparan sulfate, having the following properties: (i) sulfate group is selectively transferred from a sulfate group donor to hydroxyl group at C-6 of N-sulfoglucosamine residue; (ii) sulfate group is transferred to CDSNS-heparan, but sulfate group is not transferred to chondroitin and chondroitin-4-sulfate; (iii) optimum reaction pH is in a range of pH 6-7; (iv) optimum ionic strength is in a range of 0.1-0.3 M (in the case of sodium chloride); and (v) the enzyme activity is inhibited by dithiothreitol and adenosine-3',5'-diphosphate, and activated by protamine. | 2 |
RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Patent Application No. 61/390,277, filed Oct. 6, 2010, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to apparatus to handle clothing and more specifically to an apparatus and method of drying and sanitizing sports gear.
[0003] After using sports equipment, the equipment may get wet and sweaty. To keep such equipment well maintained and ready to use again safely, drying and sanitizing the equipment is well recommended.
[0004] It would be desirable to have an apparatus for drying and sanitizing personal sports equipment.
SUMMARY OF THE INVENTION
[0005] In one aspect of the present invention, a device to dry equipment includes an upward-extending rack; a support base to support the rack; a plurality of arms on the rack to support the equipment; an ozone generator; and an enclosure to retain the ozone near to the equipment.
[0006] In another aspect of the present invention, a device to dry sweat from clothing includes an upward-extending rack; a support base to support the rack; a plurality of arms on the rack to support the clothing, the arms angled like the arms of a tree; an ozone generator; and a removable, flexible enclosure that covers the rack and is secured to the rack so as to retain the ozone near to the clothing.
[0007] In yet another aspect of the present invention, a method of drying equipment includes supporting the equipment upon arms of an upward-extending rack; generating ozone; and enclosing the rack within a removable enclosure that retains the ozone near to the equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 depicts a perspective view of an embodiment of a drying and sanitizing sports gear apparatus in use according to the present invention;
[0009] FIG. 2 depicts an embodiment of the unloaded apparatus of FIG. 1 ; and
[0010] FIG. 3 depicts an embodiment of the drying rack of FIG. 1 .
DETAILED DESCRIPTION
[0011] The preferred embodiment and other embodiments, which may be used in industry and include the best mode now known of carrying out the invention, are hereby described in detail with reference to the drawings. Further embodiments, features and advantages will become apparent from the ensuing description, or may be learned without undue experimentation. The figures are not necessarily drawn to scale, except where otherwise indicated. The following description of embodiments, even if phrased in terms of “the invention” or what the embodiment “is,” is not to be taken in a limiting sense, but describes the manner and process of making and using the invention. The coverage of this patent will be described in the claims. The order in which steps are listed in the claims does not necessarily indicate that the steps must be performed in that order.
[0012] Broadly, an embodiment of the present invention generally provides an apparatus and a method for drying and sanitizing personal sports gear.
[0013] As depicted in FIG. 1 , an embodiment of a drying and sanitizing sports gear apparatus 10 may include a drying rack 20 . Drying rack 20 may have a support base and may extend upward like a tree with angled arms. When the apparatus 10 is in use, sports equipment 30 may be set on the arms, such as gloves, skates, pads and helmet. The support base may be cross shaped or star shaped. Embodiments of drying rack 20 may be constructed from tubular material such as pipes, which may be perforated or open ended. Air and ozone may be blown into the equipment for drying and sanitizing. An ozone generator 16 may be coupled to drying rack 20 . The coupling could be a direct connection or with a hose 18 . A flexible enclosure 12 may be placed over the drying rack 20 , which may be loaded with sports gear/equipment 30 and secured at the bottom to contain the ozone for the duration of a treatment. The flexible enclosure may be a leak proof plastic bag that may be secured at the base with a fastener.
[0014] As depicted in the embodiment if FIG. 2 , drying rack 20 may extend upward like a tree with angled arms. A support base and the arms may be reconfigured to accommodate different types of equipment. The apparatus 10 may be used as a drying/sanitizing rack for sports equipment and other items worn by humans such as coats, shoes, boots, or any article of clothing that need to be dried and or sanitized. The ozone generator 16 may be customized with options such as timers, variable output levels, fan speeds. Longer exposure to ozone and or to higher concentration of ozone increases the effectiveness of sanitization. The flexible enclosure or cover 12 could be commercially available household plastic bag or it could be custom made from airtight material with zippers or tent like features. Fastener 14 is provided to secure flexible enclosure 12 over drying rack 20 . Cinching strap, adhesive tapes and likes could be used as fastener 14 .
[0015] As depicted in the embodiment of FIG. 3 , a drying rack 20 shape and height may be reconfigurable to accommodate varying type of sport gears and equipments. In one implementation, the height of drying rack 20 stands approximately 4.5 feet tall. Drying rack 20 may be made of several tubular materials such as metal or polyvinyl chloride (PVC) piping. Drying rack 20 may be assembled from a plurality of commercially available parts, hollow tube/pipes 22 , hollow tube/pipe fittings 24 , end caps 26 and hooks or clasps 28 .
[0016] Another aspect of the present invention provides a method for drying and sanitizing personal sports gear. The method may allow setting a duration of a sanitization time. It may also provide a means to set an optimum ozone level provided by the ozone generator.
[0017] Embodiments of a rack may have an approximate height of 50″, and width of 24″. A 57″×37″ plastic cover may utilize a ratchet clip to close the cover at the bottom. Embodiments may be for personal, home use, such as a stand which is no more than the height of a person's suit of clothing, such as 6 feet tall. This may allow the drying and sanitizing sports gear apparatus may also be used for drying or sanitizing a single set of clothing worn by people such as coats, shoes, boots, etc. The area of application of the sports gear apparatus may be directed toward personal use; however its broader commercial use is also feasible.
[0018] An embodiment of a personal sports gear drying and sanitizing apparatus may comprise: a drying rack having a support base and an upward extended tree-like armed structure, with at least one arm; an ozone generator coupled to drying rack; a flexible enclosure removably covering the drying rack; and a fastener securing the flexible enclosure at the support base. | An apparatus and method of drying and sanitizing sports gear or other clothing includes an upward-extending rack; a support base to support the rack; a plurality of arms on the rack to support the clothing, the arms angled like the arms of a tree; an ozone generator; and a removable, flexible enclosure that covers the rack and is secured to the rack so as to retain the ozone near to the clothing. | 3 |
FIELD
[0001] This invention relates generally to finger printing technology, and more particularly to finger print image acquisition.
BACKGROUND
[0002] The main purpose of law enforcement at a crime scene is to document, preserve, and collect evidence. An important part of such evidence is the collection of latent fingerprints. These prints are used to identify individuals who were at the crime scene. For this process to work, there must be a database or library of known fingerprints on file. To compile such a database, the fingerprints (and now palm prints) of every person arrested for a criminal offence are taken during the booking process. The equipment used to capture the prints is predominantly electronic with the use of a “Live Scan” device, having a transparent glass surface for acquiring high-resolution images of fingers and palms pressed against the transparent glass surface.
[0003] Live Scan fingerprinting enables capture of fingerprints and palm prints electronically, without the need for the more traditional method of ink and paper.
[0004] In the US, most law enforcement agencies use Live Scan technology as their primary tool in the recognition of persons. Live Scan is commonly used for criminal booking, sexual offender registration, civil applicant, and background checks. In the UK, many major police custody suits are now equipped with Live Scan machines, which enable suspects' fingerprints to be instantly compared with a national database.
[0005] The old method using ink and paper for obtaining fingerprints used ink to transfer the elevated ridge detail of a person's hand to paper that was later scanned into the Automated Fingerprint Identification System (AFIS) database. The new Live Scan method scans the hand directly into the system without ink. The same Live Scan machines are also used to acquire and record fingerprints of people for jobs or licenses, such as firearms permits, and the problems described below apply to these uses as well.
[0006] A Live Scan device captures images of only the part of the hand (such as a finger or a palm) that makes contact with the glass, and produces an image of just the raised ridges, the raised ridges being used to identify the person. However, if there is interference with the skin making full contact with the glass of the live scanner device, a poor image of the identifying ridges will result.
[0007] With the present use of Live Scan devices to capture the image, the key issues have become: skin quality of the person being fingerprinted, and substances that may be found on the skin of the person being fingerprinted. There are a few problems that can arise when attempting to acquire an image of a fingerprint or a palm print using a live scanner device:
[0008] 1. Images can be Too Light
[0009] This can happen due to lack of moisture on the skin, which causes the image to show up very light, and in some cases the image can be so light as to be unreadable.
[0010] 2. Images can be Too Dark
[0011] Excess sweat, water, oil, or any moisture can cause the image to darken to the point where the ridge lines come together and produce a black spot in the image, or blacking out an entire area of the image.
[0012] 3. Missing Areas in the Image—
[0013] When skin is peeling, or has a callused area such areas can show up blank, or too light to see. Finger joint areas that are slightly recessed but nevertheless have ridge lines that can provide information are often not imaged at all.
[0014] 4. Inconsistent Image Darkness—
[0015] If the entire area scanned does not have a consistent moisture level, then the image will have light and dark areas that make the image of the print hard to see and/or hard to understand.
[0016] If any one of the issues above are present with enough severity, then the scan will be rejected and the scan must be redone. When dealing with an uncooperative subject, or someone who is under the influence of drugs or alcohol, this becomes not only an inconvenience, but can become an officer safety issue if the subject becomes agitated that the process is taking too long.
[0017] Attempted Solutions
[0018] 1. Images can be Too Light—
[0019] Plain or distilled water can be applied with a fine mist from a spray bottle. When water is used on some live scan devics, it is too difficult to apply without over-applying and causing the entire area to turn black, and so a lot of time is spent waiting for the skin to dry enough to proceed. Lotions or oils by themselves are nearly impossible to apply without using too much, thereby causing the same black out effect. Other products, such as Ridge Builder™ or EZ Scan™ are in liquid form, and are therefore easily spilled and require thorough washing and then drying of the hands prior to and after application. Some of the current products available have a large amount of alcohol (as much as 98.2%), which can be dangerous to keep in a jail or a prison where the product could be consumed easily or splashed into an Officer's eyes due to it being in liquid form. High alcohol content can also pose a serious problem when the breathalyzer is being used during a booking procedure.
[0020] 2. Images can be Too Dark—
[0021] This issue will remain constant even without the use of an additional product. This issue can be solved by cleaning the hands prior to scanning, thereby drying out the skin, possibly resulting in images that can be too light.
[0022] 3. Missing Areas in the Image—
[0023] To have the Live Scan device pick up on the missing areas from a callused area of the hand, the same techniques for dealing with light images have been used, and similar problems are experienced. Moreover, joint areas still fail to be imaged.
[0024] 4. Inconsistent Image Darkness—
[0025] The problem posed by products that are currently available is that it is difficult to apply such products evenly so as to produce consistent image darkness. When a liquid product is applied, the goal is to apply the product evenly. It if is not applied evenly, the image will be dark in some spots while light in others. When water is used, three outcomes are possible. One is that if the person has any lotion, contaminants, dirt, or oil on their hand, the water mixes with them to produce a mud-like substance, resulting in a mess on the glass, thereby producing unusable images. Also, the water is absorbed into some areas of the skin faster than others, and in some areas the water remains on the surface and causes blotchy images. Further, the water must be applied several times on each hand because it evaporates quickly, which wastes time and becomes frustrating to the person being printed.
[0026] The problems introduced by the use of water, or products presently available, is that while in some cases they may work, they work only inconsistently throughout a fingerprinting session, and depend on the person to be fingerprinted being willing to cooperate throughout the session, which cannot be relied upon.
[0027] Latent fingerprints from crime scenes that are collected by law enforcement officers worldwide are not always perfect, and are not always complete prints. Sometimes, all the print examiner has to work with is a small portion of a suspect's fingerprint. Consequently, if the library of fingerprints on file is of poor quality, or has missing areas due simply to a bad scan, then there is a greater chance that no match will be found, and a crime could go unsolved.
SUMMARY
[0028] The preparation of the invention enables Automated Fingerprint Identification Systems (AFIS) and Integrated Automated Fingerprint Identification Systems (IAFIS) Live Scan machines to capture more detailed and complete fingerprint and palm print images, usually on the first attempt. The preparation of the invention provides clear, crisp, dark, and detailed images of fingers and palms pressed against the glass of a Live Scan machine. The preparation of the invention can reveal more accurate minutiae and discernable patterns, and this additional data is easily incorporated into the AFIS database. The preparation of the invention is a waxy solid that is most advantageously dispensed in stick form, that can be easily applied evenly to fingers and palm, and that can remain on the skin for an entire session of fingerprinting and palm printing using a Live Scan machine. It is good for the skin, and does not need to be washed off or removed after use. Use of the preparation reduces the amount of rejected prints, and increases the number of high quality prints.
[0029] Databases of fingerprints are only as good as the images scanned into the system. If a scanned image of a fingerprint bears too many defects and gaps (missing minutia), the scanned image is useless in that it cannot be used to identify an individual.
[0030] When dealing with applications or licensing issues, the ability to capture a better image of a person's fingerprint can lessen the chance of a rejected application, and saves time and money. More importantly, this is not a problem where the solution can just save a few dollars to the user, or save time on doing a task—improved print image quality due to the use of the preparation of the invention could save lives. With higher quality fingerprint images in the database, a person who commits a crime will have a better chance of being apprehended before they can offend again.
[0031] Finger joint areas that are slightly recessed but nevertheless have ridge lines can now be imaged, thereby providing further information for use in identification. In particular, the area below the first crease of the fingertip is almost never present on a scan without some sort of product applied. While other products can be used to enhance images of this portion of the finger, the same problems arise, such as alcohol content, toxic materials, evaporation, uneven application, over application, etc. The preparation of the invention avoids all of these problems. Good imaging of this portion of the finger is very important when matching latent fingerprints from crime scenes that may only include information from this portion of the finger, so without the use of an image enhancement formulation, there would be no data to compare with the original scan.
[0032] Use of the preparation of the invention on dry skin results in darker print images that would typically be too light.
[0033] Use of the preparation of the invention prior to scanning provides an even contrast over an entire scan image.
[0034] Use of the preparation of the invention prior to scanning allows users to attain passing scans more often with fewer rejected scans.
[0035] Use of the preparation of the invention prior to scanning enables users to obtain highly optimized images of fingerprints and palm prints.
[0036] Use of the preparation of the invention prior to scanning results in scan images having crisp images of print ridge detail.
[0037] Use of the preparation of the invention avoids over-application by being presented to the fingers and palm in solid form, unlike all other known preparations for enhancement of Live Scan images.
[0038] A general aspect of the invention is a preparation for enhancement of imaging of finger prints and palm prints on a transparent surface of a live scan device. The preparation includes a mixture of: beeswax; squalane; jojoba oil; and tea tree oil.
[0039] In some embodiments, the preparation consists of a mixture of: 20%-70% beeswax; 1.0%-50% squalane; 1.0%-10% jojoba oil; and 0.1%-5.0% tea tree oil.
[0040] In some embodiments, the preparation consists of a mixture of: 60% beeswax; 30% squalane; 9% jojoba oil; and 1% tea tree oil.
[0041] In some embodiments, the mixture is solid at room temperature, and is molded into a shape that facilitates application to at least one of a finger and a palm of a person.
[0042] In some embodiments, the beeswax is replaced by at least one of: Carnuba Wax, Candelilla Wax, Pola Wax, Rice Bran Wax, Soy Wax, emulsifying wax NF (e-wax).
[0043] In some embodiments, the squalane is replaced by one of: glycerin, sorbitol, sodium hyaluronate, urea, alpha hydroxy acids.
[0044] In some embodiments, the squalane is replaced by a mixture of: Hydrogenated Poly (C6-14 Olefin); Olea Europa (Olive) Fruit Extract; Beta-Sitosterol; and Mixed Tocopherols.
[0045] In some embodiments, the jojoba oil is replaced by at least one of: olive oil, canola oil, grapeseed oil, safflower oil, argan oil, coconut oil, babassu oil, camellio oil, sunflower oil, flaxseed oil, vegetable oil, avocado oil.
[0046] In some embodiments, the jojoba oil is replaced by a mixture of: Limnanthes Alba (Meadowfoam) Seed Oil; Hydrogenated Poly (C6-14 Olefin); Olea Europa (Olive) Fruit Extract; Beta-Sitosterol; and Mixed Tocopherols.
[0047] In some embodiments, the tea tree oil is replaced by one of: thymol crystals, Zinc, Urea.
[0048] Another general aspect of the invention is a preparation for enhancement of imaging of finger prints and palm prints on a transparent surface of a live scan device, where the preparation consists of a mixture of: 60% beeswax; 30% squalane; 9% jojoba oil; and 1% tea tree oil.
[0049] In some embodiments, the mixture is solid at room temperature, and is molded into a shape that facilitates application to at least one of a finger and a palm of a person.
[0050] In some embodiments, the beeswax is replaced by one of: Candelilla Wax, Rice Bran Wax, Soy Wax.
[0051] In some embodiments, the squalane is replaced by a mixture of: Hydrogenated Poly (C6-14 Olefin); Olea Europa (Olive) Fruit Extract; Beta-Sitosterol; and Mixed Tocopherols.
[0052] In some embodiments, the jojoba oil is replaced by a mixture of: Limnanthes Alba (Meadowfoam) Seed Oil; Hydrogenated Poly (C6-14 Olefin); Olea Europa (Olive) Fruit Extract; Beta-Sitosterol; and Mixed Tocopherols.
[0053] In some embodiments, the tea tree oil is replaced by one of: thymol crystals, Zinc, Urea.
[0054] Another general aspect of the invention is a preparation for enhancement of imaging of finger prints and palm prints on a transparent surface of a live scan device, the preparation being a solid mixture of: a moisturizer to swell the ridges of the skin; an oil augmenter to add to the oil on the ridges of the skin, which are to be pressed against the glass of the Live Scan machine to create dark image lines; and a waxy matrix to be admixed with the moisturizer and the oil augmenter so as to keep the entire mixture solid at room temperatures, while facilitating transfer at least the moisturizer and the oil augmenter to the skin of fingers and palms to be printed when the solid mixture is applied thereto.
[0055] In some embodiments, the preparation further includes an antimicrobial agent to prevent the moisturizer and the oil augmenter from spreading and promoting the growth of microbes.
[0056] In some embodiments, the oil augmenter is jojoba oil.
[0057] In some embodiments, the moisturizer is squalane.
DETAILED DESCRIPTION
[0058] The preparation of the invention has been formulated to have the following attributes:
[0059] Moisturizes the skin so as to allow for higher print image quality on an AFIS Live Scan machine.
[0060] Includes antimicrobial ingredients to maximize sanitary conditions.
[0061] Has a high melting point so it will remain solid so that it can work effectively even in hot climates.
[0062] Includes no alcohol so that it is safe to use around a breathalyzer without distorting test results.
[0063] Contains no harmful or toxic ingredients, and so it is safe for use in secure locations, such as jails, prisons, booking areas, or mental institutions.
[0064] Will not stain clothing.
[0065] Has all plastic packaging that is safe for use in jails or police stations.
[0066] Can be packaged and used in “stick” form, like a deodorant stick or a lip balm.
[0067] Will not spill, splash, leak, or dry out.
[0068] Can dispense more uses per stick than can be dispensed by containers of competing preparations.
[0069] The above attributes are achieved by an elegant formulation that serves to:
[0070] 1. Swell ridges on the surface of the fingers and palm using a moisturizing agent. Even worn ridges swell enough so as to allow better detail to be captured by a Live Scan machine.
[0071] 2. Replace or augment the natural oils typically found on the skin of fingers and palms, resulting in images of sufficient darkness even in dry or callused areas, without leaving excess residue. This is accomplished by using an oil found in nature that is very similar to sebum, the oily substance normally found on skin.
[0072] 3. Inhibit the growth and spread of germs by including an antimicrobial agent, without the use of alcohol that can distort the results of a breathalyzer test.
[0073] 4. Dispense as a waxy solid in the form of a convenient easily controllable applicator stick, resembling a solid deodorant stick or solid lip balm dispenser.
[0074] To meet these objectives, a preferred formulation includes a mixture of:
[0075] Squalane to moisturize and thereby swell the ridges of the skin;
[0076] Jojoba Oil to augment the oil on the ridges of the skin, which are to be pressed against the glass of the Live Scan machine to create dark image lines;
[0077] Tea Tree Oil to serve as an antimicrobial agent to prevent the moisturizer and oil augmenter from supporting or promoting the growth of microbes; and
[0078] Beeswax to be admixed with the moisturizer, the oil augmenter, and the antimicrobial so as to keep the entire mixture solid at room temperatures, while transferring at least the moisturizer and the oil augmenter to the skin of fingers and palms to be printed when the solid mixture is applied thereto.
[0079] Ideally, the formulation will be a mixture consisting of:
[0000]
Beeswax
60%
Squalane
30%
Jojoba Golden Oil
9% (The “Golden Oil” is the Jojoba oil that is first
produced from the extraction from seed
before it is refined. 100% cold pressed
jojoba -- virgin jojoba oil -- is a clear golden color.)
Tea Tree Oil
1%
[0080] This mixture is a solid with a melting point of about 122 degrees F. Thus, the finished product will not melt at room temperature (25 degrees C.), and that is why it can be formed as a stick. Beeswax has a melting temperature of around 62 degrees C. The other three ingredients are liquid oils at room temperature (25*C).
[0081] The effective range (Min-Max) of each ingredient percentage that would still result in an effective formulation is:
[0000]
Beeswax
20%-70%
Squalane
1.0%-50%
Jojoba Golden Oil
1.0%-10%
Tea Tree Oil
0.1%-5.0%
[0082] Beeswax has a high binding strength and exhibits excellent ability to emulsify, improve structure, provide oil retention, and facilitate mold release for stick applications. Suitable substitutes for Beeswax include: Carnuba Wax, Candelilla Wax, Pola Wax, Rice Bran Wax, Soy Wax, emulsifying wax NF (e-wax), or any other wax or mixture of waxes that has a similar melting point that can hold the other ingredients in suspension, maintain solid form during storage and use, and allow a controlled and even application of the mixture to be applied to the skin. Beeswax was chosen also because it is non-toxic and inexpensive, and can hold the other ingredients in a suspension while allowing a precise and small measured amount of the other ingredients to be applied to the skin, consistently with each application.
[0083] Processed beeswax was chosen due to it being inexpensive, easy to procure, as well as providing consistent samples that do not vary due to other outside factors. For example, organic beeswax can have inconsistencies due to being unrefined.
[0084] If the beeswax or substitute was not included in the formulation of the invention, the other ingredients of the formulation would be in liquid form, and consequently it would be difficult to control the application of the formulation to the skin precisely, and it would be difficult to limit the amount of the formulation applied to the skin, and it would be difficult to prevent leaks and spills, and thus the formulation without beeswax or an equivalent would not work as well as the solid form.
[0085] Squalane is an excellent moisturizer, helping to swell the ridges of the skin with moisture, soften the skin, and restore natural protective barrier properties against environmental stresses. It stimulates healing and soothes the skin. One substitute for Squalane is a mixture of: Hydrogenated Poly (C6-14 Olefin); AND Olea Europa (Olive) Fruit Extract; AND Beta-Sitosterol; AND Mixed Tocopherols. Other substitute moisturizing agents that are able to remain in suspension with the other ingredients, and provide moisture in a measured and even amount to the skin can also be used. Squalane was chosen because it is an excellent moisturizer and emollient. It is important to provide moisture to the fingers and palm to be printed so as to plump and swell key features of a person's skin surface in a controlled manner. This results in more contact of the ridges with the glass of the Live Scan machine, and less contact of the non-raised portion of the skin, resulting in more detail acquired by the Live Scan device. This particularly enhances the image of skin that is worn or elderly, and therefore relatively smooth prior to application of an embodiment of the formulation of the invention.
[0086] Suitable substitute for squalane can be any other moisturizing agent, especially any ingredient that contains a humectant, such as glycerin, sorbitol, sodium hyaluronate, urea, and/or alpha hydroxy acids. Some squalane is derived from fish. A favorable form of squalane is derived from the olive plant, or other suitable plant.
[0087] However squalane was chosen because it is found naturally in the skin, the ease and speed of absorption into the skin, as well as the absence of alcohol, which other known formulations actually include, even though the presence of alcohol in known formulations can interfere with breathalyzer testing.
[0088] If squalane (or other suitable moisturizer) was not included in the formulation of the invention, the amount of oil used (whatever that oil may be), would have to be increased to the point where it would be too soft and too greasy to use. Alternatively, if the oil percentage was not increased, the lack of squalane would leave the beeswax (or it's substitute) way too hard and difficult to apply. Consequently, such a formulation without squalane or equivalent moisturizer would not work well enough to swell the ridges of the skin on the finger, and so would fail to enhance imaging of the fingerprint and/or palm print.
[0089] Jojoba Oil has very good effects on the skin, acting as a moisturizer and emollient agent to improve skin elasticity and suppleness. Also, Jojoba oil is chemically very similar to sebum as naturally found in skin. Thus, it augments the oiliness of skin in a very natural way. Jojoba contains natural tocopherols to minimize oxidation, and thereby reduces rancidity caused by lipid peroxidation. Jojoba oil can be replaced by a mixture of: Limnanthes Alba (Meadowfoam) Seed Oil; Hydrogenated Poly (C6-14 Olefin); Olea Europa (Olive) Fruit Extract; Beta-Sitosterol; and Mixed Tocopherols, or any other oil or oily mixture that is able to remain in suspension with the other ingredients and provide oil augmentation in a measured and even amount to the skin. Jojoba oil was chosen because of close chemical similarity with the oils found in sebum that is secreted when a person sweats. Thus, Jojoba oil adds to or replaces oils normally secreted by the body, and thereby darkens images acquired by a Live Scan machine.
[0090] Suitable substitutes for jojoba oil can be any other oil able to be held in suspension with the other ingredients that can be applied evenly in controlled amounts to the skin, thereby allowing a darker image to result. Suitable substitute oils include one or a mixture of: olive oil, canola oil, grapeseed oil, safflower oil, argan oil, coconut oil, babassu oil, camellio oil, sunflower oil, flaxseed oil, vegetable oil, avocado oil.
[0091] However, jojoba oil was chosen as the preferred oil because it is relatively lightweight and thin, as well as almost exactly replicating the properties of oils found in sebum, a substance commonly found in and on the skin.
[0092] If Jojoba oil or an equivalent was not included in the formulation, the formulation would be effective, but not as effective as the complete formulation, since the oil in the skin as augmented by the jojoba oil is what darkens the image, thereby providing more print information. However, there may be enough oil in the other ingredients of the formulation of the invention, such as Tea tree oil or squalane, or equivalents, that the formulation without jojoba oil or an equivalent could still provide modest performance.
[0093] Tea Tree Oil is a proven anti-bacterial, anti-fungal, anti-viral, and anti-inflammatory. Applications include acne, wounds, Methicillin-resistant Staphylococcus aureus (MRSA), dandruff, and hand/body washes. Tea tree oil was chosen because it is non-toxic, and promotes a sanitary condition on the stick of the mixture without harsh chemicals or alcohol. Although thymol crystals could also be used, thymol crystals are more expensive and not readily available.
[0094] Tea tree oil substitutes can be any antimicrobial agent able to be added and held in suspension that can discourage the growth of bacteria and other germs. Suitable substitutes include: thymol crystals, Zinc, and/or Urea.
[0095] However, Tea tree oil was chosen due to its easy availability and lower cost.
[0096] If an antimicrobial agent was not included in the formulation, the formulation would still work, but there would be more of a risk of the spread of disease due to bacteria or other disease organisms due to contact of the stick with the skin of many persons.
[0097] To use the preparation of the invention in solid stick form, first remove the cap from the dispenser (such as found in many solid deodorants, or solid lip balms) to expose an end of the solid stick of the preparation. Apply the end of the solid stick to the surface to be printed of each finger, and optionally to the palm to be printed. For example, one can run the stick up one side of a finger, and down the other side, repeating for each finger. The preparation can be applied to the palm using a zig-zag pattern, for example. Next, using a glove that is resistant to degradation by oil, rub all surfaces with a gloved thumb so as to ensure that the preparation is evenly spread over all surfaces to be printed using the Live Scan machine.
[0098] Although the best form to present the preparation of the invention to the fingers is a solid stick of the formulation, the formulation can also be contained in a shallow container with an opening large enough to enable application to each finger by wiping the pad of each finger on the surface of the preparation in the shallow container. The container is shallow so that the walls of the container do not interfere with the wiping action of a finger over the solid surface of the preparation. Alternatively, the container can be sized so that it can accommodate an entire hand to be printed, including all fingers and the palm.
[0099] Other modifications and implementations will occur to those skilled in the art without departing from the spirit and the scope of the invention as claimed. Accordingly, the above description is not intended to limit the invention, except as indicated in the following claims. | A preparation is provided for enhancement of imaging of fingerprints and palm prints acquired using a Live Scan device. The preparation is solid at room temperature, even in hot climates, and can be consistently applied. The preparation is a mixture of: 20%-70% beeswax; 1.0%-50% squalane; 1.0%-10% jojoba oil; and 0.1%-5.0% tea tree oil. The mixture can be advantageously molded into a shape that facilitates application, such as the shape of a deodorant stick or lip balm. Preferably, the preparation consists of: 60% beeswax; 30% squalane; 9% jojoba oil; and 1% tea tree oil. The preparation moisturizes skin to facilitate higher quality images on AFIS or IAFIS Live Scanners, and includes an antimicrobial to maximize sanitary conditions, includes no alcohol to be safe to use around a breathalyzer, is non-toxic for use in jails and mental institutions, and will not stain clothing. | 0 |
This is a divisional of application Ser. No. 07/849,750, filed Mar. 12, 1992, U.S. Pat. No. 5,404,893 which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates primarily to a method and apparatus for controlling the automatic addition of detergent into a commercial warewashing machine. There are two key problems addressed by the invention. One is the detergent addition itself. The other is the determination of an appropriate concentration set-point. By making the detergent feed dependent upon the real-time concentration change rate, detergent overuse is reduced during the detergent addition. Adjusting detergent concentration set-points to correspond to changing account conditions also helps to maximize the performance of the warewashing process.
2. Description of Related Art
It is known in the art to provide warewashing machine systems with detergent controllers. Typically, such systems operate in an on-off mode, proportional mode or a combination thereof. The systems control the detergent concentration level to a pre-set detergent concentration level (set-point). The systems do not compensate for varying chemical injection rates and therefore exceed this set-point. They indirectly sense detergent concentration by measuring solution conductivity. The major perceived benefits of this type of controller is that the addition of, and concentration maintenance of, detergent to the warewashing machine is achieved without manual intervention.
However, these controllers do have some major shortcomings. The detergent concentration set-point consists of a single pre-set value for all wash cycles. Unless the set-point is manually reset, the wash items are subjected to the same concentrations of detergent in the wash solution, regardless of the meal period or type of soil present on the wash items. Therefore, to be certain of maintaining an acceptable cleaning result, the set-point is selected for a worst case condition. This results in detergent overuse. In addition, the detergent controllers feed detergent based on proportional control, reacting to the relationship between the setpoint and the current concentration. They do not compensate for the detergent feed rate which also causes detergent overuse or excessive wear on the feeder equipment.
SUMMARY OF THE INVENTION
To overcome the limitations in the prior art described above, and to overcome other limitations that will become apparent upon reading and understanding the present specification, the present invention discloses a programmable detergent controller for varying the detergent concentration set-point according to the date and time. The controller sensor, a conductivity sensor with an imbedded thermistor, is capable of not only detecting detergent concentration and wash temperature but also water changeovers, machine run time, and detergent consumption. The present invention also discloses a programmable detergent controller for optimizing detergent concentration without incurring overshoot. Thus, the present invention insures that the warewashing machine is operated at optimum efficiency and cost.
The present invention combines the features of a microprocessor, clock and controller into one unit. The present invention provides a controller with the ability to change detergent concentration set-points according to the time of the day. The present invention also provides a detergent controller with the ability to reach a detergent concentration level quickly without incurring overshoot.
A feature of the present invention is a controller which may be programmed with a variable detergent concentration set-point. A further feature of the present invention is a controller which senses the detergent concentration and dispenses the proper detergent amount to the warewashing machine. An advantage of the present invention is the ability to change the detergent concentration set-point to correspond to the meal period or other special needs. Another advantage of the present invention is the ability to calculate the appropriate detergent feed time based on the rate of detergent concentration change.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
FIG. 1 is a diagram showing the interconnection between the warewashing machine and the monitoring system;
FIG. 2 is a block diagram of the variable detergent concentration set-point system incorporating a microprocessor, a clock and a detergent on-time controller; and
FIG. 3 is a flow chart diagram describing how the controller calculates the appropriate detergent feed time based upon the previous response and a programmed on-off set-point.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description of the preferred embodiment, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration a specific embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
The preferred embodiment of the present invention provides a system to control detergent concentration set-points for warewashing machines with respect to time. The present invention leverages the sensing capability of the detergent controller by adding a microprocessor and a clock into the controller unit. By programming different detergent concentration set-points for different times of the day, the variable detergent concentration controller can more effectively remove soil from the wash items.
The preferred embodiment of the present invention also provides a system to control the detergent concentration level without overshooting a pre-set detergent concentration level. Detergent injection rates vary with temperature, concentration and other factors. The latency time that results from the feeder equipment injection delays and product dissolution rates is not accounted for in previous detergent controllers. The present invention compensates for any latency time without exceeding the detergent concentration set-point. Those skilled in the art will recognize that the present invention could be used with any type of warewashing machine.
FIG. 1 discloses the preferred embodiment of the present invention as used in a typical warewashing system. The preferred embodiment includes a detergent controller 12 that incorporates a microprocessor 10 and a clock 20 within a housing unit 8. The controller 12 also includes a solenoid valve 6 within the housing unit 8 to control the detergent feed to the warewashing system.
FIG. 2 more particularly illustrates the block diagram of the preferred embodiment as used in a variable detergent concentration set-point system. The preferred embodiment includes a microprocessor 10 for determining an appropriate detergent concentration set-point. The microprocessor 10 receives two types of inputs from the user. First, a particular detergent concentration set-point 14 is entered into the microprocessor 10. Then, a user time setting 16 is entered into the microprocessor 10. The user time setting 16 instructs the microprocessor 10 to begin using the corresponding detergent concentration set-point at the time entered.
Next, the preferred embodiment includes a clock device 20 that provides the microprocessor 10 with a signal corresponding to the date and time 22. The microprocessor 10 compares the date and time signal 22 to the user time setting 16. When the clock date and time signal 22 coincides with the user time setting 16, the microprocessor 10 loads the corresponding detergent concentration set-point 14. The detergent controller 12 uses this corresponding detergent concentration set-point 14 until the microprocessor 10 determines that another set-point should be used. Thus, the controller 12 can be programmed to handle soil loads that vary cyclically with time. The number of time and set-point entries are limited only by the storage capability of the microprocessor.
A sensor 24 routes a measurement of the detergent concentration and temperature information 28 to the microprocessor 10. The sensor 24 preferably comprises a conductivity sensor and an imbedded thermistor. The conductivity sensor signals the detergent concentration 28 by determining conductivity using the measurement of the free ions in the wash tank 40 solution. The imbedded thermistor signals the temperature information 28 by determining the temperature of the wash tank 40 solution.
In the preferred embodiment, the conductivity sensor may be of an electrode or electrode-less type. An electrode-type conductivity sensor is typically comprised of two electrodes immersed in the wash tank 40 solution, wherein the current flow from one electrode to the other electrode corresponds to the conductivity of the solution. An electrode-less conductivity sensor, which operates as a transformer, is typically comprised of a primary coil inducing a current into the wash tank 40 solution and a secondary coil converting the current into a voltage level, wherein the voltage level corresponds to the conductivity of the solution.
The microprocessor 10 uses the conductivity and temperature information 28 provided by the sensor 24 to determine wash tank 40 changeover, detergent consumption, and detergent feed.
With regard to wash tank 40 changeover, the microprocessor 10 can determine when the wash tank 40 has been recharged with fresh water using the detergent concentration 28. Typically, the same solution is used over and over for multiple racks of dishes. The sensor 24 senses the fresh water because of the resulting change of the solution to a very low conductivity or a major reduction in conductivity.
With regard to detergent consumption, the detergent concentration 28 from the sensor 24 can also be used to determine when a detergent reservoir is empty. If the sensor 24 detects a decrease in conductivity, even though the warewashing machine has been instructed to feed detergent into the wash tank 40, then there is probably no detergent being fed into the wash tank 40. However, it could be the situation that someone just recharged the detergent reservoir, but some air has gotten into the feed line; it is also possible some of the detergent was solidified and it is just eroding slowly in the wash tank 40 solution; or it is possible that there are other causes of low conductivity. Thus, the microprocessor 10 can be programmed not to indicate an empty detergent reservoir unless the wash tank 40 solution remains at a low conductivity level for some period of time. Other criteria can also be used.
With regard to detergent feed, the microprocessor 10 compares the corresponding detergent concentration set-point 14 with the detergent concentration 28 from the sensor 24. Based on this comparison, the microprocessor 10 determines when the solenoid valve 6 should be opened to allow the feeding of detergent solution 30 into the wash tank 40 and sends a open command 26 to the solenoid valve 6.
FIG. 3 is a flow chart describing the steps performed by the controller 12 (shown in FIGS. 1 and 2) during detergent feed to achieve yet, not exceed, a pre-set detergent concentration level. There must be a balance between overshoot and the need to reach a suitable detergent concentration quickly to insure adequate washing performance on the first items through the process.
Instead of fixed or adjustable crossover points to proportional mode or adjustments to output response protocols, the controller 12 dispenses detergent only by calculating the required feeder on-time, based on the last known flow-rate. After, or in some cases during a detergent feed cycle, the detergent flow-rate is calculated and either the detergent feed time is modified for the current detergent feed cycle or it will be used for the next detergent feed time calculation. This allows the controller to avoid any on-off type proportioning, and instead use derivative control to achieve the detergent concentration set-point quickly and with minimal overshoot. It also inherently gives the controller 12 the capability to optimize detergent feed for any of a variety of configurations and system lags without the need to predict them in advance. This learning and comparing cycle is performed each time the controller 12 activates a solenoid valve 6, thus allowing a change to the controller 12 response function if and when conditions change, such as water pressure or temperature. The special challenges in the warewashing application require the controller 12 to make up wide differences between the actual detergent concentration 28 provided by the sensor 24 and set-point as quickly as possible, again without exceeding set-point. Aggravating the process is a latency time between activating the deteregent feed and reading the detergent concetration information 28 at the wash tank sensor 24. The detergent feed rate can vary greatly and must be compensated for.
The controller 12 first reads an interrupt condition 50, FLAG 3. FLAG 3 is an indication for the controller 12 to activate the solenoid valve 6 to allow the feeding of detergent solution 30 into the wash tank 40. If FLAG 3 has not been set, then the controller 12 is in the "control" state and the intermediate flow-rate calculation 60 begins immediately. If FLAG 3 has been set, then the controller 12 determines whether the solenoid valve 6 will be activated for longer than 2 seconds 52, given the last known flow-rate (FC), the current detergent concentration (DC) and set-point (DS). If the detergent feed will not be ON longer than 2 seconds, then the controller 12 does nothing 54. If the controller 12 determines that the solenoid valve 6 will be activated for longer than 2 seconds, the controller 12 initiates the output (Detergent Feed) and FLAG 3 is cleared 56. An output ON time (SET-TIME) is then calculated 58.
Next, the intermediate flow-rate calculation is initiated 60. If the controller 12 determines that the flow-rate has increased to the point where overshoot occurs, then the detergent feed is terminated 62. If the flow-rate has not increased, the accumulated ON time (Ta) is incremented 64 and compared with the SET-TIME 66. If the accumulated ON time is not greater than the SET-TIME, then the flow-rate calculation continues. However, if the accumulated ON time is greater than the SET-TIME, the detergent feed is terminated 62. Whenever the detergent feed is terminated in the above steps 62, the OFF-TIME timer (To) is incremented 68 and the controller 12 determines whether the flow-rate should continue to be calculated 70 by determining whether FLAG 2 has been set. If FLAG 2 has not been set, the flow-rate calculation continues 72. Otherwise, the remaining OFF-TIME is compared to the latency time as discussed below 90. When the flow-rate calculation is resumed 72, the detergent concentration 28 is read every 0.1 seconds. The value of the detergent concentration 28 is then stored in a memory location indicated by a pointer A 72. The pointer A is then incremented to the next memory location so that the number of stored detergent concentration 28 values can be counted 74. Once thirteen detergent concentration 28 values have been stored (A>12), then an intermediate flow-rate (Fco) is calculated 76. If Fco has not exceeded 35 microsiemens per second or FLAG 1 is not set 78, the flow-rate is deemed to have not changed and the latency time (LT) is incremented 80. The maximum latency time permitted is 20 seconds. If the output is ON and some latency time has accumulated, but not exceeding 20 seconds 82, then intermediate flow-rate calculation is repeated (back to 60). If the flow-rate is deemed to have changed or ifthe latency time is greater than 20 seconds, the flow-rate is set to the latest flow-rate 84 and FLAG 1 is set to stop accumulating latency time. With the output OFF, the latency time (LT) and flow-rate (FC) calculations continue if there are more than 2 seconds of OFF-TIME (To) remaining 86 and the OFF-TIME is not greater than the latency time 90. If there are not more than 2 seconds of OFF-TIME remaining 86, then FLAG 2 is set 88. If the OFF-TIME is greater than the latency time 90, the flow-rate is cleared 92. The accumulated on-time, off-time, the storage device, FLAG 1, and FLAG 2 are also cleared 92. The latency time is then reset to one 94. Finally, FLAG 3 is set 96 and recalculation begins again 52 by determining if the detergent feed will be on longer than two seconds, given the last known flow-rate (FC), the current detergent concentration (DC) and set-point (DS).
In summary, the present invention is a detergent controller having the ability to change the detergent concentration set-point to correspond to meal periods, as well as weekend and holiday workloads. The invention incorporates a microprocessor, a clock and controller in one unit. Thus, in addition to detecting and recording warewashing machines performance data, the unit can be programmed to control different set-points at different time settings. The present invention also controls detergent levels by balancing overshoot of the detergent set-point with the need to reach a suitable detergent concentration quickly. By optimizing the detergent concentration level without incurring overshoot, the controller insures adequate washing performance on the first items through the process, and reduces chemical feeder wear.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It 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. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
Those skilled in the art will recognize that the present invention could be used with different components or combinations of components than those described above. Those skilled in the art will also recognize that other user interfaces and storage devices and different combinations thereof, could be substituted for the interfaces and storage devices used in the preferred embodiment. | An apparatus and method for programming a detergent controller to vary the detergent concentration set-point according to the time of day and to achieve detergent concentration levels quickly without incurring overshoot. Thus, the present invention insures that the warewashing machine is operated at optimum efficiency and cost. To vary the set-point according to the time of day, the invention combines the features of a microprocessor, a clock and a controller into one unit. The user enters the time setting and set point into the controller. The microprocessor then compares the real-time clock signal with the user time settings and outputs an appropriate set-point value from the microprocessor to the controller. To achieve detergent concentration levels quickly without incurring overshoot, the controller senses the detergent concentration and dispenses the proper detergent level to the warewashing machine according to a predetermined detergent feed time based on the previous response time and the programmed set-point. Thus, the controller can change the response function if and when conditions change. | 3 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
The present invention relates to optical solar reflectors for earth satellites.
Most satellites which operate in earth-o-bit require some form of environmental control to maintain a thermal balance between the satellite components and the extremes of the low temperature space background and the radiative flux from the sun. These satellites employ a variety of standard techniques including thermal control coatings, radiators and multilayer insulation (MLI) to achieve this thermal balance. These thermal control systems utilize a variety of materials depending upon application and configuration but they generally have similar properties of lightweight, low outgassing, and high UV stability. Consequently, most of the subsystems have not been designed with any need for very high temperature stability.
With the advent of ground and spaceborne High Energy Laser (HEL) threats, most of the standard materials and techniques commonly used become vulnerable to severe degradation resulting from the high flux and fluence levels. As a result, active and passive countermeasures such as evasive actions or higher temperature materials must be used to withstand or avoid this new environment.
A common technique for obtaining stable, low solar absorptivity to emissivity ratios (α s /ε) has been the Optical Solar Reflector (OSR). Typical values of α s /ε are 0.08/0.8. The OSR are typically applied in tiles about 1 inch square, consisting of 6 to 8 mil of high purity fused silica as a substrate with a coating of silver on its rear surface to form a second surface mirror. The tiles are bonded to the radiator surface with an adhesive. Since the OSR has high emittance in the IR region of the spectrum, it inherently absorbs at a longer wavelength (SiO 2 absorbs very strongly beyond 5 μm and heats up rapidly when exposed to laser radiation in this region). Large differences in thermal expansions of silica and silver films cause delamination at the silica/silver interface.
It is therefore an object of the present invention to provide an improved Optical Solar Reflector (OSR).
Other objects, aspects and advantages of the present invention will be apparent to those skilled in the art.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided an improved Optical Solar Reflector (OSR) comprising a silicon nitride (Si 3 N 4 ) tile having a reflecting metallic coating applied to its rear surface.
Also in accordance with the present invention there is provided an improved OSR comprising a transparent silicon nitride tile having a reflecting metallic coating on its rear surface and having a reflectivity enhancement coating on its front surface.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing, the FIGURE is a cross-sectional view of the improved OSR of this invention.
DETAILED DESCRIPTION OF THE INVENTION
The Optical Solar Reflector (OSR) of the present invention is adapted to form the exterior surface or coating of a satellite or other space vehicle for the purpose of providing temperature control. The OSR is bonded in tile-like fashion to the exterior skin of a satellite, where it is effective to radiate heat which is generated within the satellite, as for example, by electronic equipment, while at the same time reflecting incident solar radiation to which the satellite is subjected when in a space environment. The size of the tiles depends upon the requirements of their installation, the range from 0.5 inch square up to about 4 inches square covering most installations. The tiles are attached to the exterior skin of the satellite using a high temperature, low outgassing adhesive, preferably one which has at least some flexibility to allow for possible differences in thermal expansion between the OSR and the skin of the satellite.
Referring now to the drawing, the OSR of the present invention, designated generally by the reference numeral 10, comprises a substrate layer 12 of silicon nitride (Si 3 N 4 ), preferably crystalline silicon nitride, with a reflecting metallic layer 14 applied to its rear surface. Optionally, a protective antitarnishing layer 16 of chromium, Inconel or alumina may be applied to the outside of the reflective layer 14. Thus, according to one embodiment of this invention the OSR 10 comprises substrate layer 12, reflecting layer 14 and the optional protective layer 16. According to another embodiment of the invention, the OSR 10 further comprises a front surface dielectric coating 18 consisting of a plurality of alternating layers of thorium fluoride 20 and zinc sulfide 22. In a presently preferred embodiment, the coating 18 consists of a total of six of the alternating layers.
The silicon nitride layer 12 exhibits a sharp reflectance peak in the 9 to 11 micron region, while the visible transmission of such material can, in general, be made better than 80%. Fabrication of the silicon nitride tiles is by chemical vapor deposition onto a suitable target, such as graphite. Following deposition, the deposit is cut into suitably sized tiles, then lapped to a desired thickness of about 200 to 300 microns and polished to maximize the visible transmission and improve the IR reflectivity. Prior to depositing the reflective layer 14 onto the substrate 12 an optional adhesion promoting layer 24 of alumina may be vacuum deposited onto substrate 12. The layer 24 has a thickness of about 100-200 Angstroms. The reflecting layer 14 may then be vacuum deposited. This layer can be aluminum, silver, gold or the like. The protective layer 16 and the optional front surface coating 18 are thereafter applied to the OSR.
Various modifications of the present invention are possible in light of the above disclosure without departing from the spirit thereof or the scope of the appended claims. | An optical solar reflector comprising a layer of silicon nitride having a reflective metallic coating on one side thereof and an optional dielectric coating on the opposite side. | 8 |
BACKGROUND OF THE INVENTION
THIS invention relates to the multi-dimensional electronic identification of articles.
In radio frequency identification systems, a reader is typically used to read the identity of a number of objects in the form of transponders which are attached to goods to be identified, and to communicate the identification information to displays or computer networks. Communication between the reader and the transponders is by electromagnetic means, allowing transponders to be identified that are not in line of sight with the reader. Invariably, the transponders are randomly oriented, with the result that a single reader with a single energy polarisation is not capable of detecting all of the transponders. Nulls or dead zones also occur in the radiation pattern of a single reader due to interference patterns from reflecting surfaces and the like.
The problems associated with differences in polarisation and nulls or dead zones generally arise in the case of passive transponder systems, where the transponders are powered by an energising field, typically for the time period that such energising field exists. This is even more prevalent in the case of systems where transponders are effectively deactivated once they have been successfully identified, so as not to interfere with the transmissions of other transponders in the reading volume. Transponder systems of this type are described in U.S. Pat. No. 5,751,570 to Stobbe et al, U.S. Pat. No. 5,124,699 to Tervoet et al. and South African patent 93/6267 to Marsh et al.
In U.S. Pat. No. 5,519,381 to Marsh et al, a system is described that simultaneously uses at least two different interrogation signals at different frequencies to provide power to transponders in an interrogation volume. The different frequencies may be radiated from different angles, thereby compensating for dead spots and polarisation. U.S. Pat. No. 5,850,181 to Heinrich et al describes a system providing power transferred to a number of transponders by pulsing the electromagnetic field at randomly selected frequencies. The electromagnetic field is briefly turned off between frequency changes to limit spectral noise caused by the switching process. The transponders make use of an energy store to maintain the level of the operating voltage of the transponders whilst the frequency is switched between pulses.
In order to provide for low production costs, the electronic components of transponders need to be built into a single integrated circuit. As a result, the transponders have limited on-board energy storage capacity in situations where the energising field has been removed. In the absence of an on-board power supply in the form of a storage capacitor, such transponders are volatile, in that they tend to perform a power on reset when the energising field is re-established at the start of the next reading session, even when this occurs relatively soon after a prior reading session. This can lead to a single transponder being read several times in error in the case of multiple interrogation fields being utilized.
SUMMARY OF THE INVENTION
According to a first aspect of the invention there is provided an identification system comprising at least one reader defining a predetermined reading zone and a plurality of objects, wherein:
the reader includes first transmission means for transmitting a first interrogating and energising field into the reading zone and receiver means arranged to receive and identify an identification signal from at least one object; and, each object is arranged to be powered by the energising field and includes memory means, and transmission means arranged to transmit an identification signal to the reader identifying itself, the memory means being arranged to record the successful transmission or otherwise of the identification signal and to retain the record in the absence of a power supply to the object, for a time period longer than any predicted interruption of power supply to the object via the energising field within the reading zone.
In a preferred form of the invention, the reader includes second transmission means for transmitting a second interrogating and energising field from the reader, and cycling means for sequentially transmitting the first and second interrogating fields during an interrogation cycle wherein the predicted interruption of power supply corresponds to the maximum possible time period for which the object may not be powered during the interrogation cycle.
Conveniently, the reader includes at least three transmission means arranged to transmit at least three corresponding interrogating and energising fields into a predetermined volume within which the objects are to be identified, using sufficient different axes of polarisation and/or reader locations practically to cover all possible orientations and locations of objects within the volume, with the time period of the interrogation cycle including the time period taken for the sequential transmission of all but one of the interrogating and energising fields.
Typically, the objects are passive transponders which are only powered for the time period that they receive an interrogating and energising field.
Advantageously, the transmission means comprises a plurality of oriented and polarised transmitting antennas and at least one transmitter connected to the transmitting antennas for sequentially energising the transmitting antennas with a carrier wave signal of a predetermined frequency, and the receiver means includes a plurality of similarly oriented and polarised matching receiving antennas and at least one receiver connected to the receiving antennas for receipt of the identification signals from the objects, the reader further comprising processor means for processing and decoding the incoming identification signals.
The cycling means conveniently comprises first switching means for sequentially switching the transmitter between the transmitting antennas, second switching means for sequentially switching the receiver between the receiving antennas, and a switch control unit for operating the first and second switching means in concert whereby, at any one moment, matching transmitting and receiving antennas are operative to transmit and receive similarly polarised signals.
The invention extends to a method of identification of a plurality of objects by a reader comprising the steps of:
transmitting. during an interrogation cycle, a first interrogating and energising field from the reader for powering and interrogating the objects; transmitting an identification signal from at least one object in response to the first interrogation field; receiving the identification signal at the reader, and determining if the signal has been correctly received; recording at the object the successful transmission or otherwise of its identification signal and retaining the record in the absence of a power supply to the object for a time period longer than any predicted interruption of power supply to the object.
Preferably, the method comprises the steps of initiating the interrogating and energising cycle by transmitting the first interrogating and energising field from the reader and transmitting a second interrogating and energising field from the reader, with the time period of the predicted interruption of power supply corresponding to the maximum possible time period for which the object may not be powered by any interrogation field during the interrogation cycle.
Advantageously, multiple interrogation fields are transmitted into a predetermined volume within which objects are to be identified, using sufficient different axes of polarisation and/or reader locations practically to cover all possible orientations and locations of objects within the volume, with the maximum possible time period including at least the time period taken for the transmission of all but one of the multiple interrogation fields.
The method typically includes the steps of using the retained record of successful transmission to prevent the subsequent transmission of the identification signal at least for the duration of the interrogation cycle, and using the retained record of unsuccessful transmission to allow the subsequent transmission of the identification signal during the interrogation cycle.
Conveniently, the interrogation fields are sequentially cycled through during the interrogating and energising cycle, each object is only powered for the time period that it is energised by an energising field, and the memory means is arranged to be recharged by subsequent interrogation fields that it receives during the interrogation cycle for as long as it retains the record of successful transmissions.
According to a still further aspect of the invention there is provided a passive transponder for an identification system of the type comprising at least one reader defining a predetermined reading zone and a plurality of object-based transponders, the transponder being arranged to be powered and interrogated during an interrogation cycle, by at least one of a plurality of energising fields from the reader, and including re-settable short term memory means, and transmission means arranged to transmit an identification signal to the reader identifying itself, the memory means being arranged to record the successful transmission or otherwise of the identification signal and to retain the record in the absence of a power supply to the object via an energising field, for a time period longer than any predicted interruption of power supply to the object within the reading zone during the interrogation cycle.
Preferably, the short term memory means is operative to record the successful transmission of the identification signal and to retain the record to prevent the subsequent transmission of the identification signal for at least the duration of the interrogation cycle.
Conveniently, the transponder includes on-board power supply means for deriving a power supply signal for powering the transponder only for the duration that it receives a powering and interrogation field.
Typically, the transponder includes a control logic circuit connected to the short term memory means, the short term memory means being responsive to a memory set signal from the control logic circuit, and the control logic means being responsive to a memory status signal from the short term memory means, the memory set signal being generated by the control logic circuit in response to the successful transmission of the identification signal, and the memory status signal being arranged to prevent the transponder, via the control logic circuit, from subsequently transmitting the identification signal for the time period.
The short term memory means may include an RC-type circuit having a predetermined time constant proportional to the time period, and comparator means having the RC-type circuit as an input and the memory status signal as an output, whereby the memory status signal is arranged to change states in the event of the signal from the RC-type circuit falling below a reference value.
Conveniently, the memory set signal is generated each time the transponder is powered up via an interrogation signal during an interrogation cycle to prevent the transmission of the identification signal at least for the time period commencing as soon as the transponder has been powered down.
Typically, the control logic circuit includes latching means responsive to the memory status signal, the latching means further being arranged to generate the memory set signals in response to the successful transmission of the identification signal, and further being arranged to disable the transponder output for the time period that the status signal is indicative of a set short term memory status.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a highly schematic diagram of a reader and three differently oriented transponders in the interrogation field of the reader;
FIG. 2 shows a circuit diagram of a short term memory element forming part of each of the transponders;
FIG. 3 shows a series of signal waveforms indicating a number of interrogation cycles and a typical response from a short term memory element in one of the transponders;
FIG. 4 shows a schematic diagram of the manner in which scanning of the interior of a truck using the method of the invention avoids nulls;
FIG. 5 shows a schematic block diagram of a reader of the invention; and
FIG. 6 shows a schematic block diagram of a transponder of the invention.
DESCRIPTION OF EMBODIMENTS
FIG. 1 shows a reader or interrogator 10 with three Yagi antennas 12 , 14 and 16 . The antennas are positioned so that differently oriented transponders 18 , 20 and 22 are within the effective reading range or energising field of at least one of the antennas. Antenna 12 is horizontally polarised and is aligned along the x-axis 24 , antenna 14 is horizontally polarised and is aligned along the y-axis 26 and antenna 16 is vertically polarised and is aligned along the y-axis 26 . The z-axis 28 extends vertically into the page. Transponder 18 lies along the x-axis 24 , transponder 20 along the y-axis 26 and transponder 9 along the z-axis 28 . The effective interrogator field or reading range of antenna 12 is depicted by an oval footprint 29 . The effective reading range is defined as the range within which any transponder which has the correct antenna polarisation for reader antenna 12 will collect sufficient energy to power its circuitry. Thus transponder 18 will essentially receive energy from the energising field radiated by antenna 14 , transponder 20 from antenna 12 and transponder 22 from antenna 16 . The relative position of the antennas, the polarisation of the antennas and even the number of antennas is dependant on the specific application for which the transponders are being used. The three antennas are positioned to generate three interrogation fields which, in combination, define a predetermined three-dimensional interrogation volume through which transponders may be passed.
The reader 10 cycles the interrogation fields between each of the three antennas 12 , 14 and 16 . Each antenna can have its own transmitter and receiver or the reader can use an RF switch to accomplish the switching between the antennas. The frequency of the electromagnetic field is preferably the same for each antenna, although it could also be different for each antenna. The length of the reader cycle is governed by the retention time of a short term memory element in each of the transponders.
FIG. 2 shows a schematic circuit diagram of such a short term memory element 30 . If the transponder has been without power for a sufficient length of time, then capacitor C has no charge stored in it. When the transponder initially powers up, the voltage stored in capacitor C is less than Vref so the output 32 of a comparator U 1 , which is a memory status signal, is a low. A memory set signal is initially raised on power up via an input switching control line 34 . If the memory status signal is low then transponder logic 35 enables the transponder to transmit its stored data. The transponder logic 35 also holds the memory set signal high via the control line 34 .
The transponder transmits its code according to its protocol. When the transponder has successfully transmitted its identification signal and/or the reader has successfully read it, the transponder is placed into a non-responsive state using the method defined by its protocol. The transponder logic 35 lowers the memory set signal which turns on transistor Q 1 via resistor R 1 . This causes capacitor C to charge via Q 1 , diode D 1 and resistor R 2 . The capacitor C charges to a voltage V+ less the volt drops across diode D 1 and transistor Q 1 . This is higher than Vref and so the output of the comparator U 1 rises. The memory status signal at the output 32 is thus raised to a high which causes the transponder logic 35 to disable any further transmissions of its stored data.
If power is removed for a short period, the transponder circuitry will stop functioning. Capacitor C will slowly be discharged by resistor R 3 . If power is reapplied while the voltage on capacitor C is still above Vref, then the output 32 will still be high and so the transponder logic 35 will prevent the transponder from transmitting its data. The transponder logic 35 will also lower the memory set signal at the input control line 34 so as to recharge capacitor C. If, however, power is reapplied after the voltage on capacitor C has dropped below Vref, then the memory status signal will be low and so the transponder logic 35 will enable the transponder to transmit its data again. The memory set signal is kept high so that capacitor C is not recharged.
The time constant of the capacitor C and resistor R 3 is such that it will take longer than the reader cycling time to discharge to Vref, typically 2 seconds, but will have discharged below Vref within, say, 5 seconds, thus allowing the transponder to be reread. The capacitor C has a typical value of 5 pF and the resistor R 3 a value of ITΩ. It will be appreciated that any IC equivalent resistive components, such as lossy FET transistors, can be used. The reader cycling time is the time it takes the reader or interrogator 10 to cycle through a full interrogation cycle in which all three antennas 12 , 14 and 16 have been sequentially activated to cover the interrogation volume through which the differently aligned transponders are being passed. The small value of the capacitor C means that it occupies a relatively small area, and the entire short term memory element can thus be integrated into a single integrated circuit along with the rest of the transponder circuitry.
FIG. 3 shows signal waveforms of the cycling of the reader energising or interrogating fields. Waveform 12 A show the energising field for antenna 12 , waveform 14 A shows the energising field for antenna 14 and waveform 16 A shows the energising field for antenna 16 . The energising field is first switched on for antenna 12 . After time T cyc /3, antenna 12 is turned off and antenna 14 is switched on, and after time 2T cyc /3, antenna 14 is turned off and antenna 16 is turned on, after which the cycle recommences with antenna 12 . The time for the reader to cycle through all the antennas is give by T cyc . Waveform 18 A shows the operating voltage for transponder 18 which is positioned so as primarily to receive energy from the energising field of antenna 14 . At 40 , when the energising field 14 A 1 of antenna 14 is turned on, then the antenna on transponder 18 collects energy from the energising field, rectifies and smoothes the energising field and produces an operating voltage 41 for the transponder. At 42 , when the energising field on antenna 14 is turned off, then the operating voltage 41 on transponder 18 immediately drops to zero.
Waveform 18 B shows the voltage on capacitor C for transponder 18 . Transponder 18 is initially in a responsive state and is able to transmit its data to the reader since capacitor C is uncharged. At 44 , transponder 18 has been successfully read by the reader and is placed into a non-responsive state. Capacitor C is charged and so the transponder is unable to transmit any further data to the reader. At 46 , when the operating voltage drops to zero, then the capacitor C starts to discharge at a rate determined by the R3C time constant. Once the reader has cycled through the other two antennas 16 and 12 , the power is restored to transponder 18 via waveform 14 A 2 . The voltage on C is still higher than Vref and so the capacitor C is recharged at 48 as the operating voltage rises, and the transponder thus remains in a non-responsive state. If the energising field was removed for a longer period than T cyc , then the capacitor C would discharge further until its voltage dropped below Vref, as is shown in broken outline at 49 , at time T cyc +T2. The transponder would then be able to transmit its data again when the energising field is reapplied, and Vref would be higher than the R3C output voltage, as is shown at 49 A. T cyc , or the reader's cycle time, is typically 3 seconds, with each interrogation pulse having a duration of 1 second.
In the drawing, T ret is the memory retention time of the responder. This commences at 46 , when the first energising field of antenna 14 is turned off and the operating voltage 41 on the transponder 18 drops to zero, and continues up until point 49 on the time axis. In the particular example, T ret =⅔T cyc +T2. More generally, in the case of N interrogation fields being transmitted sequentially from N different antennas, with each non-overlapping interrogation field lasting for an identical time period T, then T cyc =nT, and the minimum theoretical retention time T ret =T(n−1). In the case of non-equal time periods, then the minimum theoretical retention time would equal the total cycle time less the minimum transmission time for the interrogation field having the shorter duration. In order to allow for variations in component values, temperature changes and the like, the time constant of the short term memory is calculated so that an additional time period, such as time T 2 , is added to the theoretical minimum memory retention time. In even more general terms, the minimum permissible retention time is at least the maximum possible time period for which the transponder may not be powered by any interrogation field within the interrogation cycle as the transponder passes through the reading zone. In the particular embodiment, the time to discharge capacitor C sufficiently to allow the deactivated transponders to transmit again is typically in the region of 3.5 to 5 seconds.
The above reader arrangement with three antennas is ideally suited to applications such as reading the contents of a supermarket trolley. In a supermarket trolley, each product that has been purchased incorporates a transponder. At the check-out counter, the trolley is wheeled through an interrogation volume defined by three or more antennas positioned to generate three or more interrogation fields in the manner illustrated in FIG. 1 . Typically, the three fields are mutually orthogonal. Randomly aligned transponders in the trolley, whilst generally not being individually aligned with either the x-, y- or z-axes, will invariably have an alignment which is most suited to receiving one of the polarised signals. More particularly, the alignment axis of each antenna can be broken down into x, y and z vectors, with the predominant vector determining the particular polarised interrogation signal that will predominantly be received by the transponder. In many cases, in particular where a transponder is close to two or more interrogation fields, or has a diagonal orientation which causes it to respond to two or more interrogation fields, that transponder may be read twice during an interrogation cycle, in the absence of the short term memory element 30 . The short term memory element 30 thus ensures that a transponder is read only once during a particular cycle, even if it is energised and de-energised by different interrogating fields during that particular cycle.
In an application such as the scanning of the interior of a metal boxed truck 50 , as shown in FIG. 4 , the metal wall would cause reflected energising signals to interfere with the direct energising signals, resulting in zones of low energy within the truck 50 . Antennas 52 and 54 have low energy zones 56 and 58 respectively. These zones are dependent on the position of the antennas, and will be different for differently positioned antennas. By switching between different antenna pairs during the reading, the reader can ensure that the entire contents of the truck are adequately illuminated with energising field, as long as the time taken to complete a reading cycle is less than the memory retention time of the short term memory element. The system can also be used to read items occupying a large volume, the dimensions of which are larger than the range of an individual reader, by allowing the placing of the reader antennas around the outside of the volume, which the reader scanning from all the antennas within a reading cycle.
The antennas surrounding the volume may be scanned around the volume, and may also be rotated or shifted along any predetermined path effectively to cover randomly oriented transponders within the volume. In an extreme example, a single transmit/receive antenna or a transmit/receive antenna pair may be scanned around the volume, or vice versa.
Referring now to FIG. 5 , a block diagram of a typical reader or interrogator 10 is shown. The transmitting antenna 12 B and the receiving antenna 12 C are in the same orientation and polarisation, as are transmitting antennas 14 B and 16 B and respective receiving antennas 14 C and 16 C. A transmitter 62 provides a carrier wave signal at a typical operating frequency of 915 MHz. The output of the transmitter 62 is switched by a transmitter switch 64 between transmit antennas 12 B, 14 B and 16 B. The antenna that the switch is set to radiates the carrier wave signal as an electromagnetic interrogation or energising field, which is used to power one or more of the transponders 18 , 20 and 22 , depending on the orientation of the transponders relative to the antennas. The transponders communicate by means of backscatter modulation which is received by one of the corresponding receive antennas 12 C, 14 C or 16 C, depending on which antenna is busy radiating. A receive switch 66 switches the received signals from the receive antennas to a receiver 68 . The receiver then sends the received signals to a processor 70 , which decodes the incoming data. A switch control unit 72 is controlled by the processor 70 , and is arranged so that it controls both the transmit switch 64 and the receive switch 66 in concert. Thus, if the transmit switch 64 is set to transmit via the transmit antenna 12 B, then the receive switch 66 will simultaneously be set so that the corresponding receive antenna 12 C is connected to the receiver. The decoded data is sent by the processor 70 to a computer 75 via a communication link 74 .
In FIG. 6 , a schematic block diagram of a typical transponder 20 is shown. The transponder data or code is stored in a data memory module 80 . An antenna 82 collects energy from the energising field 29 . A radio frequency (RF) module 84 rectifies the collected energy and filters it using a capacitor 86 to provide a DC operating voltage for the transponder circuitry for the time that the energising field is on. The capacitor has a value of around 5 pF, which is too small to continue powering the transponder after the energising field has been removed. Overvoltage protection in the form of a zener diode 88 or a similar device limits the operating voltage when the transponder is close to the reader. An oscillator 90 provides a clock signal 92 for the transponder circuitry.
When the transponder is initially powered on, a “successfully read” latch 94 is cleared which causes a memory set signal 34 A to be raised. The voltage of capacitor C in the short term memory element 30 is a zero which causes the memory status signal 32 A to be low, so the “successfully read” latch 94 remains cleared. Since the output of the “successfully read” latch 94 is low, then the output of a Manchester encoder 98 is enabled via an enable signal 99 from the latch 94 .
The pseudo random number generator 100 times a random delay time. When the delay time expires, the pseudo random number generator 100 sends a trigger signal 102 to the control logic 35 which causes the control logic to start transmitting the transponder data in the following manner. The control logic 35 sends a shift clock signal 104 to the data memory 80 which serially shifts the data 106 out of the data memory 80 . The data 106 is exclusive or'ed with the clock signal 92 in the Manchester encoder 98 . The output of the Manchester encoder 98 drives the modulator 108 . The modulator 108 varies the loading on the antenna and so modulates the backscatter from the antenna with Manchester encoded transponder data. When all the transponder data has been transmitted, the control logic 35 stops the shift clock 104 .
If the reader 10 is able to successfully receive and decode the transponder identification data, then it communicates to the transponder by means of a protocol that it has been successfully read. Alternatively, successful transmission of the transponder identification signal may be “signalled” by the absence of an “interrupt” signal from the reader. Successful transmission and receipt of the identification signal causes the “successfully read” latch 94 to be set. The setting of the “successfully read” latch 94 causes the memory set signal 34 A to be lowered, which charges the capacitor C. The output of the “successfully read” latch 94 is raised which disables the output of the Manchester encoder which in turn prevents the transponder from transmitting its data again.
If the energising field is removed for a short period and then reapplied, then the state of the “successfully read” latch 94 is lost. However, the capacitor C in the short term memory element 30 is still charged. When the power is reapplied, the charge on the capacitor C causes the memory status signal 32 A to be raised, which in turn causes the “successfully read” latch 94 to be set. The output of the “successfully read” latch 94 is then raised which disables the output of the Manchester encoder and in turn prevents the transponder from transmitting its data. The memory set signal 34 A is also lowered, which causes the capacitor C to be recharged. In this manner the power to a transponder can be removed for a short period and the transponder will “remember” that it has been successfully read.
One of the main advantages of the invention is that it retains the dimensional advantages of a passive transponder which derives all its energy from its energising field, and is only powered for the period that it is energised by the field. As a result, the capacitor 86 may be reduced to a size in which it merely performs a smoothing function to provide a DC voltage for the time period that the transponder is energised. The memory requirements of the short term memory are minimised, to the extent that it merely needs to remember if it has successfully been read or not for the duration of an interrogation cycle, during which time the short term memory is able effectively to prevent the transponder from responding to a power on reset signal associated with transponders of this type. | An identification system is provided for identifying a plurality of randomly aligned object-based transponders ( 18, 20, 22 ) passing through a predetermined reading volume. A reader ( 10 ) includes multiple transmitting and receiving antenna arrays ( 12, 14, 16 ) which are arranged sequentially to transmit interrogating and energizing fields ( 29 ) into the reading volume, with each energizing field having a different polarisation. Each transponder ( 12, 14, 16 ) is arranged to be powered by at least one of the interrogating and energizing fields, and includes a short term memory module ( 30 ) which is arranged to record the successful transmission or otherwise of the identification signal of the transponder ( 20 ) and to retain the record in the absence of a power supply to the transponder. The short term memory module has a retention time longer than any predicted interruption of power supply to the transponder via one of the energizing fields within the reading volume. The minimum memory retention time is typically the time period taken for the sequential transmission of all but one of the interrogating and energizing fields ( 29 ) during an interrogation cycle. | 6 |
FIELD OF THE INVENTION
The invention relates to a catalyst for the oxidation of carbon monoxide (CO) at low temperatures, which is a catalytically active composition based on platinum and cobalt. The catalyst can be used in the removal of CO from hydrogen-rich gas for fuel cell technology in order to avoid poisoning the electrodes with CO. Further fields of application relate to the automobile sector in particular, to the effective removal of CO during cold starting of a diesel or petrol engine and also to air purification systems for quality control of air in interior spaces, the removal of CO in a tunnel, an underground railway, multi-story car parks or submarines.
BACKGROUND OF THE INVENTION
In recent years, environmental protection guidelines in the United States and Europe have encouraged the development of alternative energy sources for engines using hydrogen as fuel. The most modern process, having the highest efficiency for in-situ production of hydrogen, is reforming alcohols or hydrocarbons, in particular methane and diesel fuel, in combination with a water gas shift reaction (WGSR) and the selective oxidation of CO (SelOx), followed by energy generation in fuel cells. Fuel cells are significantly more energy efficient than internal combustion engines. Thus, power stations using fuel cells are able to achieve a system efficiency of 70-80%, compared to 30-37% for combustion. In the transport sector, polymer membrane fuel cells (PEMFCs) or high-temperature fuel cells (SOFCs) achieve an efficiency of 40-50%, compared to internal combustion engines (IC engines) 10 which have a present-day efficiency of 20-35%.
Polymer membrane fuel cells are compact, have a high power density and can be operated at low temperatures. However, they suffer from electrode poisoning (anodic catalyst Pt, Pt-Ru) by carbon monoxide, if the concentration of carbon monoxide is above 20 ppm. It is difficult to completely eliminate CO after reforming and the water gas shift reaction; thus, a need exists for CO removal from hydrogen-containing mixtures.
The method with the best prospects is the oxidation of CO by addition of small amounts of oxygen, but this requires highly selective catalysts that can oxidize CO without the simultaneous oxidation of hydrogen at the lowest temperature possible.
Many catalysts for the selective oxidation of CO (known as preferential CO oxidation in an excess of hydrogen, “PROX”) are known. These include systems based on gold and silver catalysts. However, these systems have the disadvantage that they have both low thermal stability and low stability under reaction conditions, which results in partial deactivation of the catalyst. A further disadvantage of these systems is that they are quite sensitive to moisture and CO 2 .
Further known catalysts are those based on copper; these systems have only a low activity with respect to the oxidation of CO below 200° C. in the presence of hydrogen. These systems, too, are very sensitive to water and in particular, CO 2 .
W. S. Epling, P. K. Cheekatamarla and A. M. Lane, Chemical Engineering Journal 93 (2003) 61-68, disclose a platinum- and cobalt-based catalyst on a support structure composed of TiO 2 , which is used for the selective oxidation of CO (PROX). A high catalyst activity was found here, but it was not possible to achieve the complete removal of carbon monoxide under reaction conditions for polymer membrane fuel cells, which can be attributed to the low selectivity of CO.
SUMMARY OF THE INVENTION
The invention includes a catalyst and process for producing a catalyst, in which a support structure is co-impregnated in an acidic medium. The acidic medium comprises at least one platinum precursor and at least one cobalt precursor, which function as catalytic components. The co-impregnation is then followed by drying and calcination of the support structure.
Tetrammineplatinum(II) nitrate and/or tetrammineplatinum(II) nitrate are preferably used as platinum precursors. Cobalt(IV) nitrate is preferably used as a cobalt precursor. Particularly good results are obtained when an aqueous solution containing tartaric acid and/or citric acid and/or malic acid is used as the acidic medium.
The material of the support structure is, in principle, not subject to any restrictions and includes silicon dioxide (SiO 2 ), zirconium dioxide (ZrO 2 ), aluminum oxide (Al 2 O 3 ), cerium oxide (CeO 2 ) and mixtures thereof. Silicon dioxide and zirconium dioxide were used because they display the highest activity and selectivity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph comparing a series of support materials laden with 2% by weight of platinum and 4% by weight of cobalt for the selective oxidation of CO (PROX).
FIG. 2 is a graph that indicates the dependence of the CO conversion on the Pt/Co ratio at a constant Pt loading.
FIGS. 3 a and 3 b are graphs of the activity of Pt/Co catalysts on SiO 2 and MCM-SiO 2 support structures.
FIG. 4 is a graph of the activity of a catalyst system, based on 10% by weight of platinum and 4% by weight of cobalt on an SiO 2 support structure.
FIG. 5 is a graph of 10% by weight of Pt and 4% by weight of Co/SiO 2 which were prepared by different processes.
FIG. 6 is an XRD spectrum of MCM materials that have been produced using DDDA-Br as surfactant at various molar ratios of Si/surfactant.
FIG. 7 is a graph of the activity of Pt-Co-MCM catalysts, which were prepared by different processes.
FIG. 8 is the XRD spectra of zirconium phosphate, which has been treated with cetyltrimethylammonium chloride (ZrP-CTMA-Cl) and didecyldimethylammonium bromide (ZrP-DDDA-Br).
FIG. 9 is a graph of the activity of catalysts on a zirconium phosphate support in the oxidation of CO.
FIGS. 10 a and 10 b are graphs of the activity of a catalyst on different support structures.
FIG. 11 is a graph of the activity of sulfated and unsulfated Pt-Co catalysts on support structures comprising zirconium dioxide or cerium dioxide/zirconium dioxide.
FIGS. 12 a and 12 b are graphs of the activities of various catalysts for the oxidation of CO at an ambient temperature (25° C.).
FIG. 13 is a graph of the activities of two catalyst systems for the oxidation of CO at an ambient temperature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The subject matter of the invention will be explained in more detail with the aid of the following figures and examples, without restricting the scope of the invention to the specific embodiments indicated here. The drawings include fractional numbers, with both a “,” and “.” as placeholders.
FIG. 1 shows, with the aid of a graph, a comparison of various support materials laden with 2% by weight of platinum and 4% by weight of cobalt for the selective oxidation of CO (PROX).
FIG. 2 shows a graph that indicates the dependence of the CO conversion on the Pt/Co ratio at a constant Pt loading in PROX.
FIGS. 3 a and 3 b shows the relative activities of Pt/Co catalyst compositions on SiO 2 and MCM-SiO 2 support structures under PROX conditions at the indicated temperatures.
FIG. 4 shows the activity of a catalyst system based on 10% by weight of platinum and 4% by weight of cobalt on an SiO 2 support, structure, produced by co-impregnation with H 2 Pt(OH) 6 , cobalt nitrate and nitric acid. The activity was determined under PROX conditions.
FIG. 5 shows a comparison of the activity under PROX conditions of Pt/Co catalysts (10% by weight of Pt, 4% by weight of Co on a SiO 2 substrate), which have been produced by various processes. The abbreviations used here have the following meanings:
PC-3-3: Impregnation with Pt(NH 3 ) 4 (NO 3 ) 2 , Co(NO 3 ) 2 and citric acid;
PC-3-5: Co(NO 3 ) 2 in ammonia→calcined at 400° C.→Pt(NHO 3 ) 4 (OH) 2 ;
PC-3-9a: Impregnation with H 2 PtCl 6 →calcined at 400° C.→Co(NO 3 ) 2 in ammonia;
PC-3-10b: Impregnation with H 2 PtCl 6 and citric acid→calcined at 400° C.→Co(NO 3 ) 2 and citric acid;
PC-3-11: Impregnation with Co(NO 3 ) 2 →calcined at 400° C.→Pt(NH 3 ) 4 (NO 3 ) 2 ; and
PC-3-12: Impregnation with Pt(NH 3 ) 4 (OH) 2 →calcined at 400° C.→Co(NO 3 ) 2 in ammonia.
FIG. 6 shows an XRD spectrum of MCM materials (ordered mesoporous materials), which have been produced using DDDA-Br (didecyldimethylammonium bromide) as a surfactant at various molar ratios of Si/surfactant. The abbreviations used here have the following meanings:
1:DDDA-Br/Si=0.8; 2:DDDA-Br/Si=0.5; 3:DDDA-Br/Si=0.3; 4:DDDA-Br/Si=0.1; and 5:DDDA-Br/Si=1.2.
FIG. 7 shows activity of Pt-Co-MCM catalysts under PROX conditions, which were produced under different conditions. The abbreviations used here have the following meanings:
MCM-2: 15% Pt, 6% Co, using H 2 Pt(OH) 6 , nitric acid+citric acid, cobalt nitrate;
MCM-3: 10% Pt, 4% Co, using H 2 PtCl 6 , citric acid and cobalt nitrate;
MCM-5: 20% Pt, 6.7% Co, using citric acid→calcined at 550° C.→addition of cobalt nitrate;
MCM-7: 15% Pt, 6% Co, using H 2 Pt(OH) 6 , nitric acid+citric acid, and cobalt nitrate;
MCM-10: 10% Pt, 4% Co, using tetrammineplatinum nitrate and cobalt nitrate;
MCM-12: 15% Pt, 6.7% Co, using tetrammineplatinum nitrate, cobalt nitrate and also ammonia; and
MCM-13: 10% Pt, 4% Co, using tetrammineplatinum nitrate, cobalt nitrate and citric acid, with the molar ratio of citric acid/Pt+Co being 1.2.
FIG. 8 shows XRD spectra of zirconium phosphate, which has been treated with cetyltrimethylammonium chloride (ZrP-CTMA-Cl) and didecyldimethylammonium bromide (ZrP-DDDA-Br), with the molar ratio of Zr/P/surfactant being 2:1:1 for all samples.
FIG. 9 shows a comparison of catalysts on a zirconium phosphate support in the oxidation of CO under PROX conditions at low temperatures, comparing catalysts with platinum alone and catalysts with both platinum and cobalt.
FIGS. 10 a and 10 b show a graph of catalysts based on different support structures for the oxidation of CO under PROX conditions at low temperatures.
FIG. 11 shows a graph of the activity in the oxidation of CO under PROX conditions at low temperatures of sulfated and unsulfated Pt-Co catalysts on support structures, comprising zirconium dioxide or cerium dioxide/zirconium dioxide.
FIGS. 12 a and 12 b show, with the aid of a graph, the activities of various catalysts for the oxidation of CO at an ambient temperature (25° C.) under cold start conditions of a diesel engine. The abbreviations used here have the following meanings:
ZrS: sulfated zirconium dioxide; and
AmS: Addition of ammonium sulfate during the production of the catalyst.
FIG. 13 shows the oxidation activity of CO for two catalyst systems at an ambient temperature under conditions that would be applicable, when the invention is used as a respiratory protection system.
COMPARATIVE EXAMPLE 1
Production of a Support Structure Comprising Silicon Dioxide of the MCM Type
The MCM material was produced by the method described in the article by K. Schumacher, M. Grün and K. K. Unger, Microporous and Mesoporous Materials, 27 (1999) 201-206. This process allows the production of MCM material at ambient temperatures without hydrothermal synthesis, as a result of the use of a medium comprising water and ethanol. N-Hexadecyltrimethylammonium bromide C 16 H 33 (CH 3 ) 3 NBr was dissolved in a mixture of water and ethanol and admixed with aqueous ammonia and, subsequently, tetraethoxysilane (TEOS). The following molar ratios of the constituents were used: 1M TEOS/12.5M NH 4 OH/54M ethanol/0.4M hexadecyltrimethylammonium bromide/175M water. After stirring at the ambient temperature for two hours, the solid obtained was filtered, washed with water and dried in air at ambient temperature. The BET surface area of the sample was 1230 m 2 /g.
EXAMPLE 1
Production of Silicon Oxide of the MCM Type, According to the Present Invention
The MCM material was produced by a method analogous to Comparative Example 1, but using didecyldimethylammonium bromide [CH 3 (CH 2 ) 9 ] 2 (CH 3 ) 2 NBr (DDDA-Br), 75% by weight gel in water (Aldrich), in place of hexadecyltrimethylammonium bromide. A quantity of 16.9 g of DDDA-Br were dissolved in a solution comprising 125 ml of absolute ethanol and 90 ml of water. After stirring at ambient temperature for 30 minutes, 8% by weight of TEOS were added to the solution, while stirring intensively. After stirring for 5 minutes, 60 ml of a 25% strength ammonia solution were added to this solution, while stirring vigorously, with only partial precipitation occurring of a white precipitate. The gel formed was stirred overnight at ambient temperature, subsequently filtered off, and then dried at ambient temperature in a dry box. The DDDA-Br was removed by calcination at 500° C. for 6 hours. The BET surface area of the sample was 1860 m 2 /g.
Samples of Zr-MCM and Al-MCM were produced in the same way, with zirconyl nitrate (molar ratio of Zr/Si=1:10) or aluminum nitrate (molar ratio of Al/Si=1:5) was added before the addition of TEOS.
COMPARATIVE EXAMPLE 2
Production of Zirconium Phosphate having a Large Surface Area
Zirconium phosphate was produced by the method described in the article by Yoshinaga, R. Ohnishi and T. Okuhara, Catalysis Letters, 94 No. 1-2, (2004), 45-47. Zirconyl chloride (1M) was mixed with a 1M solution of ammonium dihydrogenphosphate at a molar ratio of P/Zr of 2:1, while stirring vigorously, to give a precipitate of zirconium phosphate. The precipitate was filtered off, washed and dried at 100° C. The sample was calcined at 550° C. for 6 hours. The BET surface area of the sample was 0.7 m 2 /g.
EXAMPLE 2
Production of Zirconium Phosphate having a Large Surface Area According to the Present Invention
The zirconium phosphate was produced as in Comparative Example 2, with zirconyl acetate instead of zirconyl chloride being additionally used together with the addition of didecyldimethylammonium bromide (DDDA-Br), in order to avoid contamination of the catalyst with chloride ions. A quantity of 61.5% by weight of zirconyl acetate solution (15% by weight of Zr, Alfa Aesar) was mixed with 20.3 g of DDDA-Br (Aldrich) in 50 ml of water at ambient temperature, while stirring. Then 23 g of H 2 NH 4 PO 4 in 200 ml of water were subsequently added to this solution. After stirring overnight, the precipitate was filtered off, washed and dried at 100° C. It was subsequently calcined at 550° C. for 6 hours. The BET surface area of the sample was 475 m 2 /g.
EXAMPLE 3
Production of the Pt-Co Catalyst on Various Oxides, According to the Present Invention
The support structures produced in Examples 1 and 2 and in Comparative Examples 1 and 2 were impregnated with a warm solution (85° C.) comprising tetrammineplatinum(II) hydroxide or tetrammineplatinum(II) nitrate, cobalt nitrate, tartaric acid and/or citric acid and/or malic acid. The citric acid and/or tartaric acid were/was added in a slight excess of 1.2 (multiplied by the stoichiometric molar ratio of citric acid/Pt+Co=1). The loading with platinum and cobalt was varied in the range from 1 to 40% by weight, and from 0.5 to 30% by weight, respectively. The samples were dried overnight at 77° C. in a dry box and finally calcined at 550° C. in air for 2 hours.
EXAMPLE 4
Examination of the Catalysts
All catalysts were tested on the laboratory scale in a fixed-bed flow reactor made of a fused silica tube (1 cm ID×5 cm L). An electric oven was used to heat the reactor. The temperature was monitored by means of a thermocouple placed in the center of the catalyst bed.
A pulverized catalyst sample, having a catalyst loading that ranged from 10 to 500 mg, depending on the catalyst density, was diluted with 1 cm 3 of silica sand and then placed in the reactor: a feed gas mixture having the following composition was introduced: 0.6% by volume of CO, 0.9% by volume of O 2 , 28.5% by volume of H 2 O, 14.5% by volume of CO 2 , 52% by volume of H 2 , and 3.5% by volume of N 2 . This methane reforming gas mixture, after the water gas shift reaction (WGSR), was used for the PROX. For the PROX test at low temperatures, the reaction mixture comprised 0.6% by volume of CO, 0.9% by volume of O 2 , 18% by volume of CO 2 , 3.5% by volume of H 2 O and 73.5% by volume of H 2 and 3.5% by volume of N 2 . The mixture of 550 ppm (0.055% by volume) of CO, 15% by volume of O 2 , 1.8% by volume of H 2 O, 3.5% by volume of CO 2 , with N 2 as balance, was used to simulate the diesel exhaust gas mixture for cold start conditions. For the tests for respiratory systems, a mixture of 0.5% by volume of CO, 20% by volume of O 2 , 1.3% by volume of CO 2 , 1.8% by volume of H 2 O in N 2 was produced and used.
A conventional flow-through setup was used to produce the gas mixture. All gases were used as high-purity gases. To set precise water concentrations in the gas line, an air humidifier was installed. The flow rates were controlled using a mass flow regulator (MKS, Munich, Germany). To avoid condensation of water, all connecting lines for the PROX test (apart from the PROX test at low temperatures) were installed in a heatable box, in which a constant temperature of 85° C. prevailed. The gases leaving the reactor were analyzed by means of an HP 6890A gas chromatograph, using Porapak Q and NaX capillary columns. Before the test, all catalysts for the PROX test were reduced in the reaction mixture at 165° C. for 15 minutes, followed by a cooling step.
The BET surface areas were measured by N 2 adsorption at 77K, using a Micromeritics 2010 ASAP apparatus. The XRD studies were carried out using a DRON 4 diffractometer with Cu-Kα radiation. The XRD patterns were recorded in the range 1-7° (2θ), with steps of 0.04° (2θ).
Building on the recognition that very good results were achieved using silicon oxide support structures, further optimizations in order to increase the activity and selectivity of the catalyst were carried out on these.
The Pt/Co ratio at a constant Pt loading of 2% by weight was first examined ( FIG. 2 ). The best activity and highest selectivity for the oxidation of CO were found at a Pt/Co weight ratio in the range from 1:2 to 4:1. Further improvements were found in the range from 2:1 to 3:1, in particular 2.5:1, which corresponds to a Pt/Co molar ratio of 0.75:1. Higher loadings with cobalt and thus a higher Co/Pt ratio lowered the activity, as can be seen from FIG. 3 b.
With regard to the loading of the catalyst with platinum and cobalt, it was found that loading with ranges from 5 to 10% by weight of platinum at a Pt/Co weight ratio of 2.5:1 gives the best results for the catalyst, when using a support structure comprising silicon oxide ( FIG. 3 a ). However, there is a strong dependence of the temperature window on the loading with platinum and cobalt here. Although a higher loading leads to lower temperatures for the complete removal of CO, the upper temperature limit for the complete removal of CO is reduced. An increase in the Pt loading to more than 10% by weight barely influences the activity, while the upper temperature limit for the complete removal of CO is significantly reduced. This results in a very narrow temperature window for the complete removal of CO under PROX conditions.
Catalysts having an optimal Pt loading of from 5 to 10% by weight are naturally more expensive to produce than customary catalysts that contain from 0.5 to 2% by weight of platinum, but these catalysts can again be used very effectively at very high space velocities. These can thus be more economically feasible than catalysts with a lower Pt loading because the catalyst weight is very low, due to the effective removal of CO at high space velocities. For example, the amounts of platinum and the costs of the catalyst are the same when a catalyst containing 10% by weight of platinum is operated at a space velocity of 200,000 h −1 , and when a catalyst containing 2% by weight of platinum is operated at a space velocity of 40,000 h −1 .
A further optimization method relates to the choice of the medium in which the co-impregnation is carried out. Thus, experiments in which an acidic medium in this case, dilute nitric acid was used were first performed. The activity found here is shown in FIG. 4 . A high activity was measured even below 100° C. under extremely high gas flow rates and at high space velocities of 200,000 h −1 . The examination of such catalysts with high activity proved to be a problem, when using a customary PROX mixture of 0.6% by volume of CO, 0.9% by volume of O 2 , 28.5% by volume of H 2 O, 14.5% by volume of CO 2 , 52% by volume of H 2 and 3.5% by volume of N 2 because of the condensation of water below 80° C. A mixture comprising 0.6% by volume of CO, 0.9% by volume of O 2 , 18% by volume of CO 2 , 3.5% by volume of H 2 O, 73.5% by volume of H 2 and 3.5% by volume of N 2 was therefore used for the PROX test at low temperatures. This mixture comprised water (saturated with water vapor at 27° C.). The reaction conditions were thus more difficult than in customary PROX experiments, since the mixture used contained more CO 2 and H 2 but less water. Water usually activates the platinum-containing catalysts in the oxidation of CO, while CO 2 and H 2 have a negative effect on the activity.
The various production methods for a platinum loading of 10% by weight and a cobalt loading of 4% by weight on an SiO 2 support structure are shown in FIG. 5 . The investigation was carried out using a PROX mixture at low temperatures. Here, it can be established that the activity depends greatly on the production method. When the order of deposition of the catalyst precursor is varied, it was found that simultaneous deposition of platinum and cobalt is preferable.
Surprisingly, it has been found that the activity of the catalyst depends greatly on the nature of the medium used for the co-impregnation. Thus, it was found that catalysts which, according to the prior art, are used in neutral or basic medium displayed only a low level of effectiveness. On the other hand, the acidic medium used according to the invention was able to give significantly higher activities.
A further improvement can be achieved by using a solution containing citric acid as the acidic medium. Citric acid not only serves to adjust the pH, but also prevents the precipitation of Pt and Co ions on the surface of the silicon oxide, as a result of the protons of the citric acid competing for the adsorption sites on the surface. The separate deposition of platinum and cobalt is thus prevented, which is of great importance, since a high activity requires good contact between platinum and cobalt. Thus, complete oxidation of CO is only observed for platinum without cobalt at temperatures above 180° C., even under otherwise optimal conditions. Furthermore, citric acid is a good complexing agent, making possible high dispersion of both platinum and, in particular, cobalt, and leads to good contact between the two components. Likewise, reduction of platinum and cobalt occurs at low temperatures above 150° C. when using citric acid, so that prior reduction by carbon monoxide or hydrogen or preferably in the reaction mixture is not necessary in order to improve the activity, owing to the reduction of the catalyst during its production and calcination.
The catalyst was treated experimentally with acids other than citric acid, for example, tartaric acid and malic acid. It was found that the Pt-Co catalyst (5% by weight of Pt and 2% by weight of Co) has the highest activity when using tartaric acid. The temperature range for complete CO conversion over the catalyst is from 50° C. to 175° C. Experiments have shown that the catalyst treated with formic acid displayed a significantly lower activity. At a higher noble metal content (10% by weight of Pt and 4% by weight of Co), the choice of acid had no significant influence on the CO conversion. When tartaric acid is used, the Pt content can be reduced significantly.
It could thus be established that co-impregnation with Pt and Co precursors, in particular tetrammineplatinum(II) nitrate or tetrammineplatinum(II) hydroxide and cobalt nitrate, in the presence of tartaric and/or citric acid result in high activity and high selectivity in the oxidation of CO.
A further optimization relates to the choice of the support structure. Thus, it was found that the activity at low temperatures of the catalyst system Pt-Co/SiO 2 using silica gel with a surface area of 520 m 2 /g, could not be improved further. Higher loadings with platinum and cobalt lead only to a narrower temperature window for this system, since the activity at low temperatures is not significantly increased, while the upper temperature for the complete removal of CO is significantly reduced, as can be seen from FIG. 3 a.
Large surface mesoporous structures of the MCM type were tested. Such mesoporous molecular sieves have large surface areas, with BET surface areas of up to 1500-1600 m 2 /g. Various samples of MCM support structures were produced using simple and advantageous methods at ambient temperatures, as described in K. Schumacher, M. Grün and K. K. Unger, Microporous and Mesoporous Materials, 27 (1999) 201-206. BET surface areas of the MCM material of up to 1150-1230 m 2 /g were therefore able to be achieved. According to the invention, these processes were then modified by using didecyldimethylammonium bromide (DDDA-Br), instead of hexadecyltrimethylammonium bromide (cetyltrimethylammonium bromide, CTMA-Br). The surfactant DDDA-Br contains two relatively short hydrocarbon chains instead of one long chain, as in the case of CTMA-Br. This enabled the surface area to be increased greatly, and a BET surface area in the range from 1640-1860 m 2 /g, depending on the molar ratio of silicon to surfactant, was achieved. This molar ratio was varied in the range from 0.1 to 1.2, with the highest BET value of 1860 m 2 /g found for a DDDA-Br/Si ratio of 0.8. These BET values are significantly higher than the values reported hitherto for support structures of MCM type or other inorganic support structures, and they come very close to the surface area values for activated carbon, which has the largest known surface areas of up to 2500 m 2 /g.
XRD analysis reveals that the phase having the greatest order was found for a DDDA-Br/Si ratio of 0.8, as can be seen from FIG. 6 , so this ratio was used as a basis for further production tests. Further surfactants having two relatively long hydrocarbon chains, e.g., didodecyldimethyl-ammonium bromide and dihexadecyldimethylammonium bromide were examined. However, it was found that these resulted in a smaller surface area. A further disadvantage is the very high costs compared to DDDA-Br, while the inexpensive technical-grade 75% gel in water (Aldrich) can be used for DDDA-Br.
The MCM material with the greatest surface area of 1860 m 2 /g was utilized for further optimization experiments. As can be seen from FIG. 7 , a significantly higher activity and selectivity could be achieved for the MCM material when completing the process using citric acid, while other processes were far less effective. Optimization, with respect to the citric acid, indicated that the best molar ratio of citric acid to total loading (platinum and cobalt) is about 1.2:1. After production of a system of this molar ratio, the catalyst displayed complete removal of CO even at 50° C. and extremely high space velocities of 200,000 h −1 under PROX conditions. Furthermore, the Pt-Co/MCM catalyst was optimized with respect to the loading with platinum ( FIG. 3 b ). It can be seen from this that an MCM support structure with a low Pt-Co loading gives no advantages. This can be attributed to the fact that it is difficult to achieve good contact between platinum and cobalt at low loadings because of the extremely large surface area of the support structure. In addition, the lower density of MCM structures compared to commercial silicon oxide leads to a lower actual Pt loading at the same Pt-Co loading and the same space velocities, since the weight of the MCM structures was smaller by a factor of virtually 2, thus, the amount of platinum also decreased.
The abovementioned high space velocities of 200,000 h −1 were not observed for any commercial silicon system, regardless of the loading with platinum and cobalt, which represents a considerable improvement compared to commercial silicon oxide. A further significant advantage of the Pt-Co catalyst on an MCM support is the wide temperature window for the complete removal of CO, due to the high activity at low temperatures and the low activity with regard to the oxidation of hydrogen. Thus, a higher temperature for the complete removal of CO can be achieved. This can range up to 170° C. even for very high Pt-Co loadings of 20% by weight of platinum and 6.7% by weight of cobalt. This can be attributed to the large surface area of MCM, which leads to the high dispersion of platinum and cobalt, even at high loadings. It can thus be established that the Pt-Co catalyst on an MCM support structure is the most promising candidate for the elimination of CO in the field of fuel cell applications. The fuel cell varies the temperature from 200° C. (typical temperature of the reformed gas from the WGSR at low temperature) to 80° C. (lowest temperature without appreciable condensation of water), while the operating temperature of fuel cells usually ranges from 50 to 80° C. The working range of a PROX catalyst should therefore be in the range from 50 to 200° C. The system Pt-Co/MCM with a BET surface area of 1860 m 2 /g and from 5 to 10% by weight of Pt and from 2 to 4% by weight of Co, covers all temperatures and space velocities for all possible PROX applications in fuel cells. This can be attributed to the high BET surface area, which allows high dispersion of platinum to be achieved and the formation of large Pt clusters with more metallic properties, leading to the oxidation of hydrogen, to be avoided. Furthermore, MCM support structures have an increased acidity, which aids the removal of CO 2 . However, it was not possible to work at temperatures lower than 50° C. for the catalyst based on platinum, cobalt and an MCM support structure because of the liberation of heat from the oxidation of CO and H 2 .
A further variant relates to the use of zirconium-based support structures. Zirconium oxide displays a good activity, but has a small temperature window, which is attributable essentially to the small surface area. In addition, zirconium oxide does not only possess strongly acid sites, but also basic sites that are not very suitable for the oxidation of CO because the removal of carbonates at the basic sites, which are formed from the surface of the catalyst during the course of the oxidation of CO, is not simple. It is therefore proposed according to the invention, that strongly acidic zirconium-containing compounds in particular, zirconium phosphate and sulfated zirconium oxide be used.
Experiments on the preparation of zirconium oxide with a large surface area using the same method of employing DDDA-Br as MCM support structures were unsuccessful, since the structures collapse and have surface areas of less than 20 m 2 /g.
Support structures comprising zirconium phosphate with large surface areas could likewise be prepared, with CTMA-Cl or DDDA-Br employed as surfactants.
Building on the process devised by Y. Kamiya, S. Sakata, Y. Yoshinaga, R. Ohnishi and T. Okuhara, Catalysis Letters, 94 No. 1-2, (2004), 45-47, which is based on the preparation of zirconium phosphate with a Zr/P molar ratio of 1:2 and a surface area of 120 m 2 /g after calcination at 400° C., this was repeated using zirconium oxide chloride and ammonium dihydrogenphosphate. The structures formed here collapse after calcination at 550° C. and lead to surface areas of less than 1 m 2 /g.
The same synthesis was then carried out with the addition of surfactants, i.e., CTMA-Cl and DDDA-Br, at a molar ratio of Zr/P/surfactant of 2:1:1. This surprisingly gave a very stable structure, having a surface area of 433 and 475 m 2 /g after calcination at 550° C. XRD analysis indicated the presence of a mesoporous structure, as can be seen from FIG. 8 . This structure has a weak order. The order was not able to be increased by hydrothermal treatment at 100° C. in the mother liquor for three days, although the surface area was significantly reduced to 210 m 2 /g, thus, this treatment is not promising.
The support structures based on zirconium phosphate were used for the Pt-Co/zirconium phosphate catalysts. The data on the activity of the catalysts produced using tetrammineplatinum(II) nitrate, cobalt nitrate and citric acid under PROX conditions are shown in FIG. 9 . Both systems i.e., those using CTMA-Cl or DDDA-Br as surfactants display excellent activity with complete removal of CO, even at 50° C. for the catalyst treated with DDDA-Br and at approximately 70° C. for the catalyst treated with CTMA-Cl. Both systems have a wide temperature window for the complete elimination of CO. A catalyst based only on platinum, which had been produced by the same process using citric acid, is far less active, as can be seen from FIG. 9 . This leads to the conclusion that the high activity is attributable to the interaction of platinum and cobalt. The catalyst described was very active, even at space velocities of 400,000 h −1 .
Sulfated zirconium dioxide cannot be produced by the same method as zirconium phosphate, because as zirconium sulfate is not precipitated under the same conditions as zirconium phosphate. Ammonia was therefore additionally used in order to precipitate sulfated zirconium hydroxide. This was then calcined at 550° C., with this temperature not being sufficient for the removal of sulfates from the catalyst. As a result, the surface area is significantly lower, namely only 70 m 2 /g. The catalyst system of platinum and cobalt on sulfated zirconium dioxide was nevertheless able to achieve good properties with regard to the oxidation of CO under PROX conditions, as demonstrated in FIG. 11 . At a loading of 10% by weight of Pt, the temperature window was, however, small because of the low surface area, while the system comprising 5% by weight of Pt, 2% by weight of Co and sulfated zirconium dioxide exhibited better properties. This strong activity of Pt-Co on sulfated zirconium dioxide was surprising, as it is generally known that sulfur compounds act as catalyst poisons for Pt catalysts in many reactions, including the oxidation of CO.
In a further step, Pt-Co catalysts on different support structures were compared with one another under PROX conditions. The BET surface areas of the various support structures are shown in Table 1.
TABLE 1
Calcination
temperature
BET surface
Support structure
T cal , ° C.
area, m 2 /g
SiO 2
550
520
Al 2 O 3
550
242
MCM-SiO 2
550
1860
(according to the
invention)
zirconium phosphate
550
475
(according to the
invention)
CeO 2
600
116
ZrO 2
375
173
CeO 2 —ZrO 2 (Ce/Zr 3:1)
375
121
TiO 2
375
152
Sulfated
550
70
zirconium oxide
Zr-MCM (Si/Zr = 10:1)
550
801
Al-MCM (Si/Al = 5:1)
550
567
It can be seen from FIGS. 10 a , 10 b and 11 that the most effective Pt-Co catalyst is based on support structures composed of zirconium phosphate or silicon dioxide of the MCM type, with both produced by the process of the invention using DDDA-Br. Pt-Co catalysts on cerium dioxide/zirconium dioxide and aluminum oxide also achieved complete removal of CO, even at temperatures ranging from 50 to 60° C. The further Pt-Co catalysts that are based on other oxides as support structures displayed lower but nevertheless good activity, particularly in the cases of cerium dioxide, silicon dioxide and zirconium dioxide.
An examination of the influence of the replacement of silicon in MCM by aluminum and zirconium is shown in FIG. 11 . It is apparent here that a lower activity was achieved than in the cases of MCM support structures based solely on silicon, but it has to be taken into account that Al-MCM and in particular, Zr-MCM have very low densities; this can be attributed to the fact that the amounts of platinum and cobalt for a Zr-MCM are smaller by a factor of 2.5, compared to an MCM based only on silicon. If, on the other hand, the same amounts of platinum and cobalt are used with a higher loading of the catalyst, the activity comes very close to this, as can be seen in FIG. 10 b.
The co-impregnation of Pt and Co precursors in the presence of citric acid can be applied to any support structure known from the prior art, with the type of support structure able to influence the activity. Thus, for example, the activity of a Pt-Co catalyst on a support structure comprising titanium dioxide is significantly lower, as can be seen in FIG. 10 a , which is attributable to strong Pt interactions with the support structure. The complete removal of CO at the lowest temperatures examined, 50° C., was observed only for zirconium phosphate, silicon dioxide of the MCM type, and cerium dioxide/zirconium dioxide.
It was not possible to achieve temperatures below 50-60° C. under PROX conditions at low temperatures because the liberation of heat in the oxidation of CO and H 2 is too high. Further studies were carried out at ambient temperatures in order to determine whether activity is still present at these temperatures. The results of these studies can be seen in FIGS. 12 a , 12 b and 13 . Two different reaction mixtures were used, with one simulating the cold start conditions in a motor vehicle with typical concentrations of the main component in the diesel exhaust gas under ideal conditions, i.e., CO, O 2 , CO 2 and water (saturated water vapor at 17° C.). The second mixture simulated a possible reaction mixture for respiratory protection systems, e.g., for firemen, with relatively high CO and CO 2 concentrations under fire conditions.
It can be seen from FIG. 12 a that some catalysts display conspicuous activity at ambient temperatures in the presence of water and CO 2 , using the mixture that imitates cold start conditions for these engines. The highest effectiveness is shown by a Pt-Co catalyst on a support structure comprising zirconium phosphate, with the complete removal of CO up to extremely high space velocities of 375,000 h −1 . Strong activity was also found for Pt-Co catalysts on cerium dioxide and cerium dioxide/zirconium dioxide (complete removal of CO up to 250,000 h −1 , aluminum oxide (up to 200,000 h −1 ) and zirconium dioxide (100,000 h −1 ). Pt-Co catalysts on an MCM support structure were less effective, even at a high loading with platinum and cobalt, though partial replacement by aluminum (Al-MCM) slightly increased the activity.
The high activities found here make possible the use of such types of catalysts very promising for applications in the motor vehicle sector in order to solve the cold start problem, since 80 to 85% of CO emissions rise here, when starting at temperatures below 100° C. Taking into account the expected sulfation of catalysts for diesel applications, the Pt-Co catalyst on zirconium phosphate is most promising because zirconium sulfate cannot be sulfated. After in-situ sulfation of Pt-Co on cerium dioxide/zirconium dioxide, it was found that strong activity for the oxidation of CO at ambient temperatures is still retained after sulfation (approximately 65,000 h −1 at complete removal of CO) ( FIG. 12 b ). On the other hand, zirconium dioxide was more strongly deactivated.
The complete elimination of CO in the presence of water and CO 2 at extremely high space velocities, and the resistance to poisoning by sulfur also makes it possible to use such catalysts for interior space air purification systems in tunnels, multi-story car parks, underground railways, etc., as high space velocities are necessary here for air circulation and ventilation.
The results of the catalyst tests for the reaction mixture, which simulates respiratory protection systems, are shown in FIG. 13 . The system with the highest activity (Pt-Co zirconium phosphate) and a system based on a β-zeolite with deposited Pt-Co were examined, taking account of the fact that a zeolite can absorb many other toxic compounds that are, for example, liberated during a fire. The activities at the same space velocities were in this case lower compared to the diesel cold start conditions owing to the CO concentration, which was about an order of magnitude higher. Nevertheless, complete CO conversion was found up to a space velocity of 45,000 h −1 for Pt-Co zirconium phosphate and up to 12 000 h −1 for Pt-Co/β-zeolite. These activities are more than sufficient for an application in which high space velocities are required. It was difficult to maintain the same temperature during the experiment because of the liberation of heat, so the temperatures rose at high space velocities.
With regard to the thermal stability, it is found that the activity at ambient temperature does not change for the catalyst based on Pt-Co/zirconium oxide after calcination at 600° C., which is completely adequate for most applications.
All the above-mentioned temperatures are measured in the catalyst bed. Numerous modifications and variations of the present invention are possible, in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | The invention relates to a catalyst for the oxidation of carbon monoxide (CO) at low temperatures, which is a catalytically active composition based on platinum and cobalt. The catalyst can be used in the removal of CO from hydrogen-rich gas for fuel cell technology in order to avoid poisoning the electrodes with CO. Further fields of application relate to the automobile sector, and in particular, to the effective removal of CO during cold starting of a diesel or petrol engine and also to air purification systems for quality control of air in interior spaces, e.g., the removal of CO in a tunnel, an underground railway, multi-story car parks or submarines. | 1 |
BACKGROUND
[0001] The subject matter disclosed herein relates to valves and, more particularly, to the attachment of hinge pin posts to a valve housing.
[0002] Flapper valves, including dual flapper valves, utilize hinge pins, which are mounted on posts for rotation of the flappers. The precision and methodology used in mounting and locating the hinge pin is critical for proper operation and longevity of the valve. In general, there are two approaches for creating the mounting features for the hinge pin: integral and non-integral posts. For integral posts, the valve housing and the posts are formed together, typically by machining. With non-integral posts, the valve housing and the posts are formed separately and then joined together, typically with one or more fasteners.
SUMMARY
[0003] A valve includes a housing with a flow passage and a hole extending into the housing; a post with a base and a hole extending into the base, the post connected to the housing; and a dowel pin which sits in the hole of the housing and extends into the hole in the post.
[0004] A method of assembling a flapper valve includes press fitting a dowel pin into a hole in a valve housing; aligning a post with a hole in the base so that the dowel pin extends into the hole in the post base; and securing the post to the valve housing with a fastener.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1A is a perspective view of one embodiment of a flapper valve.
[0006] FIG. 1B is a cross-sectional view of the flapper valve of FIG. 1A along line B-B.
[0007] FIG. 1C is a close-up view of a portion of FIG. 1B
[0008] FIG. 1D is a cross-sectional view of the flapper valve of FIG. 1A along line D-D.
[0009] FIG. 2A is cross-sectional view of a second embodiment of a flapper valve.
[0010] FIG. 2B is a close-up view of section 2 B of FIG. 2A .
[0011] FIG. 2C is a close-up view of section 2 C of FIG. 2A .
[0012] FIG. 3A is cross-sectional view of a third embodiment of a flapper valve.
[0013] FIG. 3B is a close-up view of section 3 B of FIG. 3A .
[0014] FIG. 3C is a close-up view of section 3 C of FIG. 3A .
[0015] FIG. 4A is cross-sectional view of a fourth embodiment of a flapper valve.
[0016] FIG. 4B is a close-up view of section 4 B of FIG. 4A .
[0017] FIG. 4C is a close-up view of section 4 C of FIG. 4A .
DETAILED DESCRIPTION
[0018] FIG. 1A is a perspective view of one embodiment of flapper valve 10 , FIG. 1B is a cross-sectional view of flapper valve 10 along line B-B, FIG. 1C is a close-up view of a portion of flapper valve 10 , and FIG. 1D is a cross-sectional view of flapper valve 10 along line D-D.
[0019] Flapper valve 10 includes valve housing 12 , posts 14 , hinge pin 16 , stop pin 18 , flappers 20 , dowel pins 22 , and fasteners 24 . In this embodiment, valve housing 12 includes two bores (which are not shown as they are covered by flappers 20 in FIGS. 1A-1B ) and two holes 26 which extend into housing 12 , and four bores 28 which extend through housing 12 . Each post 14 includes a base 29 and a hole 30 which extends into post 14 at base 29 . In the embodiment shown, fasteners 24 are bolts with self-locking nuts, though they can be other types of fasteners in other embodiments. For simplicity, pins are shown without cross-hatching.
[0020] Dowel pins 22 sit in holes 26 , and can be press-fit into valve housing 12 . Hinge pin 16 and stop pin 18 extend through flappers 20 , so that flappers 20 can rotate relative to hinge pin 16 . Hinge pin 16 and stop pin 18 fit into posts 14 on each end. Posts 14 connect to housing 12 by aligning so that dowel pins 22 extend into holes 30 . Posts 14 can be slip fit onto dowel pins 22 , and then fasteners 24 can be used to secure posts 14 to housing 12 . Once posts 14 have been secured to housing 12 , flappers 20 can selectively rotate around hinge pin 16 to selectively restrict or allow flow through valve 10 .
[0021] As can be seen in FIG. 1D , dowel pin 22 is cylindrical in shape and can be chamfered on one or both ends, which can help engagement with hole 30 , hinge pin 16 and/or hole 26 . Dowel pin 22 can be made of steel, stainless steel or any other material depending on valve 10 requirements. Dowel pins 22 typically extend in length at least one and a half times a diameter of dowel pin 22 into each of housing 12 and post 14 . For example, dowel pin 22 may extend twice its diameter in length into housing 12 and one and a half times its diameter in length into post 14 . The extension of dowel pins 22 into both posts 14 and housing 12 can vary depending on structural loads on posts 14 .
[0022] By using dowel pin 22 , which extends from hole 26 in housing 12 into hole 30 in post 14 , valve 10 is able to use non-integral posts while maintaining precise post 14 location for holding hinge pin 16 to maintain proper operation and longevity of valve 10 . As mentioned above, valve 10 could typically be made with either integral or non-integral posts. Integral posts require much more material and can be quite difficult to manufacture due to the shape of the housing 12 and posts 14 . Thus, making posts 14 non-integral to housing 12 can save manufacturing materials and costs, but a significant disadvantage of non-integral posts is that the location and fit of hinge pin 16 ends up being less precise as compared to integrally machined posts. This can be due to the mounting of the posts, for example, screw fasteners can cause the posts to be slightly skewed. By using dowel pin 22 , which can be press fit into housing 12 , posts 14 can be precisely aligned so that dowel pin extends into hole 30 . This greatly mitigates the disadvantages of using non-integral posts 22 in valve 10 , and can further provide shear capability and therefore better structural integrity of valve 10 , as fasteners 24 are typically not designed to be put under a shear load.
[0023] Using dowel pin 22 to connect posts 14 to housing 12 allows for a relatively simple, inexpensive and robust system for hinge pin 16 retention and allows for valve 10 to acquire the benefits of using non-integral posts 14 . Manufacturing posts 14 non-integral to housing 12 can allow for posts 14 and housing 12 to be made of different materials, for example, lower weight aluminum housing 12 and higher wear stainless steel posts 14 , for system optimization depending on needs. Using non-integral posts 12 can allow for better repairability and maintainability of valve 10 , as posts 14 can be replaced instead of having to replace entire valve housing 12 and posts 14 (as in integral system).
[0024] FIG. 2A is cross-sectional view of a second embodiment of a flapper valve 10 and FIG. 2B is a close-up view of section 2 B of FIG. 2A , and FIG. 2C is a close-up view of section 2 C of FIG. 2A . Valve 10 includes housing 12 (with holes 26 ), posts 14 (with holes 30 ), hinge pin 16 , stop pin 18 , flappers 20 , dowel pins 32 , and fasteners 24 . In this embodiment, hinge pin 16 includes bore 34 and bore 36 extending into hinge pin 16 .
[0025] Valve 10 operates in the same manner as valve 10 of FIGS. 1A-1D . However, in the embodiment of FIGS. 2A-2C , dowel pin 32 extends into bore 34 of hinge pin 16 and dowel pin 32 extends into bore 36 of hinge pin 16 . The chamfered end of dowel pins 32 engage bores 34 , 36 . Bore 34 can be shaped with a diameter just larger than the diameter of dowel pin 32 to securely fit with dowel pin 32 . Bore 36 has a larger diameter than dowel pin 32 to allow for thermal expansion, particularly when using different materials for different parts of valve 10 . In other embodiments, both bores 34 , 36 could be larger or neither bore 34 , 36 could be larger.
[0026] By extending dowel pins 32 into bores 34 , 36 in hinge pin 16 , dowel pins 32 can help to retain hinge pin 16 axially, preventing any sliding movement of hinge pin 16 within posts 14 . As in FIGS. 1A-1D , dowel pin 32 allows for the use of non-integral posts while maintaining precise post 14 location for holding hinge pin 16 . Dowel pin 32 further extends into bores 34 , 36 to provide additional support for maintaining axial location of hinge pin 16 , thereby maintaining proper operation and longevity of valve 10 .
[0027] FIG. 3A is cross-sectional view of a third embodiment of flapper valve 10 , FIG. 3B is a close-up view of section 3 B of FIG. 3A , and FIG. 3C is a close-up view of section 3 C of FIG. 3A . Valve 10 includes housing 12 (with hole 26 ), posts 14 (with hole 30 ), hinge pin 16 , stop pin 18 , flappers 20 , dowel pin 40 , and fasteners 24 . In this embodiment, hinge pin 16 includes circumferential grooves 42 , 44 extending into hinge pin 16 .
[0028] In the embodiment of FIGS. 3A-3C , dowel pin 40 is flat on one end and spherical on the other end. Circumferential groove 42 is shaped to be complementary in shape to the spherical end of dowel pin 40 . Circumferential groove 44 is larger than circumferential groove 42 to accommodate thermal expansion of 10 valve components. In other embodiments, both circumferential grooves 42 and 44 could be larger or neither circumferential grooves 42 and 44 could be larger.
[0029] By using dowel pin 40 with spherical end and circumferential grooves 42 , 44 , dowel pin 40 axially retains hinge pins 16 , and can provide for an easier assembly of valve 10 , as the rotation of hinge pin 16 would not need to be precise when setting posts 14 (with hinge pin 16 ) on dowel pins 40 .
[0030] FIG. 4A is cross-sectional view of a fourth embodiment of flapper valve 10 , FIG. 4B is a close-up view of section 4 B of FIG. 4A , and FIG. 4C is a close-up view of section 4 C of FIG. 4A . Valve 10 includes housing 12 (with hole 26 ), posts 14 (with hole 30 ), hinge pin 16 , stop pin 18 , flappers 20 , dowel pin 46 , and fasteners 24 . In this embodiment, hinge pin 16 includes bores 48 and 50 extending through hinge pin 16 .
[0031] In the embodiment of FIGS. 4A-4C , bores 48 and 50 extend all of the way through hinge pin 16 . Bore 48 is shaped to be a close fit with the outer circumference of dowel pin 46 , and bore 50 is larger to accommodate thermal expansion. As in other embodiments, dimensions and sizing of bores 48 , 50 can be different. Dowel pins 46 are of a length to extend most or all of the way through bores 48 , 50 .
[0032] Dowel pins 46 can help in both the precise location of posts 14 , and can also provide axial retention of hinge pin 16 by extending through bores 48 , 50 . Additionally, extending bores 48 , 50 all the way through hinge pin 16 may make them easier and less expensive for manufacturing.
[0033] In summary, by using dowel pins 22 , 32 , 40 , 46 to extend between valve housing 12 and posts 14 , non-integral posts can be used for valve 10 while maintaining proper post 14 and therefore hinge pin 16 position. This can help to increase life of valve and add shear strength to connection between posts 14 and housing 12 , as well as allow for the other benefits which flow from using non-integral posts, for example, the ability to optimize materials used, savings in manufacturing materials and costs, better repairability and maintainability of parts, and the ability to use common posts across similar sized valves 10 which can enable modular valve design. All of these can result in an overall increase in the life and durability of valve 10 .
[0034] While FIGS. 1A-4C show flapper valve 10 , this is for example purposes only, and other types of valves could use non-integral posts with one or more dowel pins, for example, butterfly valves.
[0035] While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. | A valve includes a housing with a flow passage and a hole extending into the housing; a post with a base and a hole extending into the base, the post connected to the housing; and a dowel pin which sits in the hole of the housing and extends into the hole in the post. | 8 |
BACKGROUND OF THE INVENTION
X-ray contrast media heretofore usable orally for cholecystocholangiography do not have the diagnostic value of intraveneously administered X-ray contrast media, although the former are more readily administered and better tolerated. X-ray examination can generally be conducted only 12-14 hours after ingestion of the contrast medium, due to slow absorption. Roentgenological visualization of the gall bladder provides less contrast than with intravenously administered X-ray contrast media. Extrahepatic bile ducts are normally detected only when a so-called double dose is used, in a low percentage of cases.
Therefore, there is a continuing need for an orally administered dosage form of X-ray contrast media having a very high contrast effect, so that the bile ducts and gall bladder are visualized simultaneously and maximum accumulation of contrast agent in the receptor organ takes place more rapidly than heretofore and is also more accurately predictable in time.
An attempt was made to introduce the contrast medium into the intestine with a large liquid volume administered simultaneously and to improve the resorption rate by administration of metoclopramide i.v. The control group received contrast media without additives. This experiment was unsuccessful in overcoming the known disadvantages of conventional X-ray contrast media.
SUMMARY OF THE INVENTION
In a compositional aspect, this invention relates, in an X-ray contrast medium adapted for oral administration comprising an X-ray contrast agent for cholecystocholangiography, in admixture with a pharmaceutically acceptable carrier, to the improvement wherein the contrast medium comprises an amount of a pharmaceutically acceptable base sufficient to neutralize the stomach acid content of a human.
In a method-of-use aspect, this invention relates to a method for orally administering an X-ray contrast medium for cholecystocholangiography comprising administering orally to the patient concurrently with the contrast medium an amount of a physiologically acceptable base sufficient to neutralize the stomach acid.
DETAILED DESCRIPTION
Simultaneous oral administration of sodium bicarbonate as a physiologically compatible base with a contrast agent accelerates resorption of the contrast agent in a statistically significant manner, as illustrated by the experimental protocol of Table I, using as an exemplary contrast medium succinic acid mono-2,4,6-triiodo-3-methylamino-N-ethylanilide.
TABLE I______________________________________Comparison of the Blood Levels of Contrast Mediumof Four Patient Groups after Oral Administrationof 3 g. of Succinic Acid Mono-2,4,6-triiodo-3-methylamino-N-ethylanilide as a MicrocrystalSuspension with Various Additional Treatments(I = No Treatment; II = 350 ml. of Tea,III = 10 mg. of Metoclopramide i.v.; andIV = g. of Sodium Bicarbonate) Addi- Blood Level tional t.sub.max (% of Treat- (Min. per C.sub.max Dose inGroup ment appl.) (mg/100 ml) Bl. Vol.)______________________________________I None 132 ± 24 11.4 ± 4.5 23 ± 8II 350 ml. 120 ± 24 10.4 ± 4.2 23 ± 11 TeaIII 10 mg. 96 ± 12 9.7 ± 2.9 30 ± 10 Metoclo- pramideIV 3 g. Na 54 ± 12 9.8 ± 2.6 33 ± 3 Bicarb.______________________________________ t.sub.max =Time of maximum blood level C.sub.max =Maximum concentration in mg/100 ml and % of dose in the total blood volume, respectively Average values ± standard deviation
From Table I, it is seen that administration of metoclopramide (4-amino-5-chloro-N-(2-diethylamino-ethyl)-2-methoxy-benzamide) produces no detectable improvement over the control. However, after administration of 3 g. of sodium bicarbonate, the maximum blood level is attained within 54 ± 12 minutes after administration. Within 30 minutes after ingestion, the blood level has risen, on the average, to 80% of the maximum value.
The difference compared to the groups which received no base/buffer, 350 ml. of tea or 10 mg. of metoclopramide, respectively, is significant. The early attainment of maximum blood level permits calculation of elimination half life of contrast medium from the blood, which varies according to the idiosyncrasies of the patients to an average of 138 ± 84 minutes. From the elimination half life and the time of the maximum blood level, the resorption half life is calculated as 18 ± 6 minutes.
The invention relates to novel oral X-ray contrast media, which contain at least one contrast agent in combination with a physiologically compatible base. The term "combination" is understood to mean the contrast agent and the base represent a dosage unit which can be administered together or separately.
Using the X-ray contrast media of this invention, a high-contrast reproduction of the gall bladder and the bile ducts is made possible simultaneously and at an exactly predictable time. Moreover, visualization of the bile ducts is attained with 2 single dose (˜3 g. of contrast medium).
Suitable contrast media include all orally administrable X-ray contrast media for cholecystocholangiography. The contrast agents for such contrast media preferably are polyiodoaromatic compounds.
Examples of suitable polyiodoaromatic compounds are N-methyl-N-(3-amino-2,4,6-triiodophenyl)-glutaric acid monoamide, N-(3-amino-2,4,6-triiodophenyl)-3-acetamido-2-methyl-propionic acid.
Most preferably, polyiodoaromatic acids on their salts are used as orally-administered X-ray contrast agents in the practice of this invention.
Salts are preferably alkali metal salts. Examples of preferred contrast agents are: succinic acid mono-2,4,6-triiodo-3-methylamino-N-ethylanilide; 2-(3-amino-2,4,6-triiodobenzyl)-butyric acid (iopanoic acid); the sodium salt of 2-(3-butyramido-2,4,6-triiodobenzyl)-butyric acid (Na tyropanoate); the sodium salt of β-[3-(dimethylaminomethyleneamino)-2,4,6-triiodophenyl]-propionic acid (Na iopodate); N-(3-amino-2,4,6-triiodobenzoyl)-N-phenyl-β-aminopropionic acid (iobenzamic acid); and the sodium salt of α-ethyl-β2-(3-acetamido-2,4,6-triiodophenoxy)-ethoxy]-propionic acid (sodium iopronate).
Suitable physiologically compatible bases/buffers are the salts of weak acids and strong bases, e.g., combinations of the following ions: Li + , Na + , K + , Mg 2+ , Ca 2+ and CO 3 2- , HCO 3 - , CH 3 COO - , PO 4 3- , HPO 4 2- , H 2 PO 4 - , tris-ethanolamine, methylglucamine, and others. Carbonates and bicarbonates, for example, NaHCO 3 , MgCO 3 , Na 2 CO 3 , are preferred, individually or in the form of mixtures.
The pharmacologically acceptable base is used in quantities sufficient to completely neutralize the content of stomach acid of the patient and optionally to provide the cation for the contrast medium acid. For a contrast medium dose of about 3-10 g., approximately 0.5-10 g., preferably 3-6 g., of buffer is utilized. For example, very good results are achieved with 3-4 g. of NaHCO 3 and a simultaneous dose of 3 g. of contrast medium acid.
The novel oral X-ray contrast media are prepared in accordance with methods generally known to those skilled in the art. For example, contrast agents are mixed with a physiologically compatible base/buffer or buffer mixture with the customary galenic auxiliary agents or the contrast medium and the physiologically compatible base/buffer or buffer mixture are compounded separately with conventional galenic adjuvants and converted to the ultimately desired dosage form.
Examples of auxiliary agents are: sucrose, highly disperse silicon dioxide, polyoxyethylene-polyoxypropylene polymers, amylose, magnesium stearate, sodium lauryl sulfate, talc, sugar, silicates, cellulose, methyl cellulose, polyvinylpyrrolidone, etc.
The forms customary in galenic pharmacy for enteral administration include suspensions, dragees, tablets, capsules, and powders.
By administering the compositions of the present invention, results are attained which have heretofore been impossible to obtain by an orally administered X-ray contrast medium.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
EXAMPLE 1______________________________________(Composition as a Powder)______________________________________(a) Succinic acid mono-2,4,6-triiodo- 3-methylamino-N-ethylanilide, micronized 3.000 g. Sucrose 4.895 g. Polyoxyethylene-polyoxypropylene polymer 0.100 g. Aromatic substances 0.005 g. 8.000 g.(b) NaHCO.sub.3 as a powder or tablet 3.000 g.______________________________________
EXAMPLE 2______________________________________(Composition as a Powder)______________________________________(a) Succinic acid mono-2,4,6-triiodo- 3-methylamino-N-ethylanilide / tris 3.580 g. Sucrose 4.895 g. Polyoxyethylene-polyoxypropylene polymer 0.100 g. Aromatic substances 0.005 g. 8.580 g.(b) (NaHCO.sub.3 as a powder or tablet 2.500 g.______________________________________
EXAMPLE 3______________________________________(Composition as a Powder)______________________________________Succinic acid mono-2,4,6-triiodo-3-methylamino-N-ethylanilide,micronized 3.000 g.NaHCO.sub.3 < 0.3 mm. 3.000 g.Sucrose 4.895 g.Polyoxyethylene-polyoxypropylenepolymer 0.100 g.Aromatic substances 0.005 g. 11.000 g______________________________________
EXAMPLE 4______________________________________(Composition as a Powder)______________________________________Succinic acid mono-2,4,6-triiodo-3-methylamino-N-ethylanilide / tris 3.580 g.NaHCO.sub.3 < 0.3 mm. 2.500 g.Sucrose 4.895 g.Polyoxyethylene-polyoxypropylenepolymer 0.100 g.Aromatic substances 0.005 g. 11.080 g.______________________________________
EXAMPLE 5______________________________________(Composition as a Tablet)______________________________________(a) Succinic acid mono-2,4,6-triiodo- 3-methylamino-N-ethylanilide 500.0 mg. Magnesium stearate 3.0 mg. Highly disperse SiO.sub.2 3.0 mg. Cellulose 100.0 mg. Lactose 94.0 mg. 700.0 mg.(b) NaHCO.sub.3 as a tablet 500.0 mg.______________________________________ Six tablets per dose.
EXAMPLE 6______________________________________(Composition as a Tablet)______________________________________Succinic acid mono-2,4,6-triiodo-3-methylamino-N-ethylanilide 500.0 mg.NaHCO.sub.3 290.0 mg.Cellulose 95.0 mg.Talc 10.0 mg.Magnesium stearate 5.0 mg. 900.0 mg.______________________________________ Six tablets per dose.
In each of Examples 1-6, a chemical equivalent of KHCO 3 , Na 2 CO 3 or K 2 CO 3 can be substituted for the NaHCO 3 .
The preceding examples can be repeated with similar success by substituting the generically and specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. | An oral dosage form of X-ray contrast medium for cholecystocolangiography comprises a constrast agent and an amount of a pharmaceutically acceptable base, sufficient to neutralize the stomach acid of the person ingesting it. | 0 |
The present invention is directed toward a spreader having an improved conveyor discharge mechanism and more specifically, toward a spreader having an improved conveyor discharge mechanism to provide an even output of material under a variety of conditions.
BACKGROUND OF THE INVENTION
Many types of conveyors are in common use for moving bulk material along a horizontal or inclined trough or channel from a point of storage to a point of discharge across an edge transverse to the trough. Among the materials commonly moved in this manner are sand, grain, salt, coal and similar materials which will flow when pushed by a conveyor. Two common types of conveyors are auger conveyors (also known as screw or worm conveyors) and flight conveyors. Both types of conveyors are well known and in widespread use; however, under certain conditions, neither is capable of evenly expelling material from the channel in which it is mounted. For example, if material is fed to a flight conveyor so that it does not completely fill the spaces between the flights, material will leave the channel in pulses with pauses between each pulse. This problem is aggravated when the conveyor runs at a slow speed where the pauses are longer and more noticeable. An auger conveyor provides a generally steady output under many conditions, but when used to move a material such as damp sand or salt which tends to clump together, the output can also be uneven as clumps form which overhang the transverse discharge edge of the channel or trough before suddenly breaking off and falling. This clumping is due to the fact that damp material overhanging the discharge edge of the channel sticks to the material remaining in the channel. Here too, the problem is particularly noticeable when the conveyor is run at a slow speed due to the presence of empty spaces, between the flights. These problems make such conveyors unsuitable for applications which require a steady, even output of material from the conveyor unless a metering device of some sort is used to compensate for the irregularities in the output rate. Such metering devices add to the cost and complexity of what is otherwise a simple system.
One application where conveyors, especially auger-type conveyors are used is in conjunction with spreaders for spreading sand or rock-salt on roads. The auger may be mounted at the bottom of a V-shaped container on a truck bed or in a dump truck to move salt or sand toward the back of the truck where it is dropped across a transverse dispensing edge onto a spinning distribution plate or directly onto the road. Alternately, the auger can be mounted transversely at the front or back of a dump unit of a dump truck to move salt to one side of the truck and onto a distribution plate or chute to direct the salt onto the road. When salt or sand is being dispensed at a high rate, material is expelled fairly evenly across the transverse dispensing edge and small fluctuations in the flow caused by clumpiness or the flighting passing over the edge of the channel are unnoticeable. However, when the auger is turning at a slower speed, these irregularities will cause material to be distributed unevenly on a road surface. That materials such as salt and sand are often stored outdoors and used in inclement weather increases the likelihood that they will be damp and not flow evenly. Even material which flows freely will not be dispensed at a steady rate due to the way that material is distributed between the flights of the auger. This can result in icy patches remaining on a roadway after a salt spreader passes or require that material be wastefully applied at a higher rate than necessary in order to ensure adequate coverage. It is therefore desirable to provide a spreader with a conveyor which provides an even flow of material at low output rates but is also capable of distributing material at high output rates.
SUMMARY OF THE INVENTION
The foregoing problems and others are addressed by the present invention which comprises a channel or trough extension having a dispensing edge at an acute angle to the channel axis which evens the flow of material leaving the conveyor channel by increasing the length of the dispensing edge and slowing the instantaneous dispensing rate of the material while keeping the average rate constant.
Material is dispensed when it passes over the dispensing edge. When the dispensing edge is normal to the direction of material flow, material tends to be dispensed in pulses. This is because the amount of material between the flights varies, with more material immediately in front of a flight and little or no material directly behind it. By providing a channel extension having a dispensing edge angled with respect to the direction of flow of the auger axis, a relatively constant output rate is achieved. This is because the distance between the flight and the dispensing edge varies for points laterally spaced across the channel. It thus takes longer for some portions of material to reach the dispensing edge than for other portions. The angled edge thus serves to stagger the times at which material is dispensed and prevents large pulses from passing over the edge all at once. The extension may be constructed as an integral part of the channel or trough itself or it may comprise a movable plate which can be moved away from the channel under high output conditions where fluctuations in flow are less noticeable.
In a first embodiment of the invention, the extension comprises a plate bent to generally conform to the shape of the terminal end of a channel or trough and pivotably mounted so that it may be swung away from the channel when not needed.
In a second embodiment, the plate has a shape similar to the plate in the first embodiment, but is slidably mounted beneath the conveyor channel for storage in a non-use position and may be extended from beneath the channel to a use position when needed.
It is therefore a principal object of the present invention to provide an improved conveying device for dispensing particulate material at an even rate.
It is another object of the present invention to provide a device of the foregoing character for evenly dispensing particulate material and which device functions over a range of different feed or dispensing rates.
It is a further object of the present invention to provide a device of the foregoing character having a conveyor channel extension configured to provide a steady flow of material from the channel.
It is yet a further object of the present invention to provide a conveyor channel extension having a dispensing edge at an acute angle to the direction of material discharge to promote an even distribution of particulate material by delaying the dispensing of a portion of the material.
It is yet another object of the present invention to provide a device of the foregoing character for use with an auger type conveyor to promote a steady output rate of particulate material at low auger speeds.
It is still another object of the present invention to provide a device of the foregoing character which is attachable to an existing conveyor of a spreader for evenly spreading particulate material on a road surface at low application rates.
It is a further object of the present invention to provide a conveyor channel extension of the foregoing character in the form of a movable plate mountable at the end of a conveyor channel for displacement between use and non-use positions relative thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects of the present invention will become apparent after reading the following description of the invention in connection with the accompanying drawing in which:
FIG. 1 is a schematic side elevation view of a truck having a spreader according to the present invention mounted thereon;
FIG. 2 is a perspective view of the dispensing end portion of an auger and channel for use with a spreader as shown in FIG. 1 and having an extension plate according to the present invention positioned for use;
FIG. 3 is a perspective view similar to FIG. 2 and showing the extension plate moved away from the channel for bulk conveying;
FIGS. 4A and 4B are plan views of the auger and channel in FIG. 2 schematically showing how the plate delays the dispensing of a portion of material to provide an even output rate.
FIGS. 5A and 5B are plan views of the auger and channel in FIG. 3 schematically showing how the auger dispenses clumps of material when the plate is not in use;
FIG. 6 is a plan view of the spreader portion shown in FIG. 2;
FIG. 7 is a plan view of the spreader portion shown in FIG. 3;
FIG. 8 is an end elevation view of the spreader portion shown in FIG. 2;
FIG. 9 is an end elevation view of the spreader portion shown in FIG. 3;
FIG. 10 is a plan view of the extension plate of a spreader according to the present invention;
FIG. 11 is an elevation view of the extension plate;
FIG. 12 is a side elevation view of the extension plate;
FIG. 13 is an end elevation view of a spreader illustrating a second embodiment of an extension plate according to the subject invention; and
FIG. 14 is a plan view of the spreader and extension plate shown in FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein the showings are for the purpose of illustrating preferred embodiments of the present invention only and not for the purpose of limiting same, FIG. 1 schematically shows a spreader S which comprises a hopper H mounted on a truck T for spreading material M such as salt, sand, or cinders on a road R. Hopper H includes an open top channel 10 running longitudinally along the bottom thereof, slanted side walls 12 for directing material into the channel, and an auger 14 mounted therein and rotatable about an axis A for moving material M toward an opening 16 at the rear of the channel. The auger moves material along the channel causing it to fall out of opening 16 onto road surface R or onto a rotating broadcasting apparatus 18 which spreads the material in a broad pattern. Such spreaders are in widespread use alone or in connection with snowplow equipped trucks for ice and snow removal and are well known in the art.
FIGS. 2 and 3 show, in detail, channel 10, auger 14, and opening 16. Channel 10 comprises generally vertical side walls 20 connected by an arcuate channel bottom 22. Opening 16 is bounded by several walls so that material passing through opening 16 drops downwardly toward a road surface or a distributing device such as broadcaster 18. These walls include an inner wall 24 which meets channel bottom 22 to provide an arcuate lip or edge 26 transverse to axis A, side walls defined in part by axial extensions of channel side walls 20 beyond wall 24, and on one side, by a wall portion 28 depending from the corresponding channel side wall 20, and an outer end wall 30 attached to channel side walls 20 and wall portion 28. Walls 24, 28 and 30 extend downwardly of channel bottom 22 and serve to direct material M downwardly at the discharge end of auger 14. End wall 30 includes a laterally inner slot 32 and a laterally outer slot 34 for the purpose which will be described hereinafter. End wall 30 also includes a support pin 40 which, in conjunction with a support pin 42 on inner wall 24, serves to support a pivotal chute 44, or other directional devices that are well known in the art, and which chute in the present embodiment directs material M onto broadcaster 18.
As can best be seen in FIGS. 6 and 7, auger 14 comprises a sleeve 52 disposed around a shaft 46 and suitably secured thereto for rotation therewith, and a helical flighting 54 running the length of sleeve 52. Flighting 54 has a width B normal to axis A and includes a front face 56, a rear face 58 and a helical edge 60, and the flights have a pitch length B and a pitch angle PA relative to axis A. Pitch angle PA is preferably around 75 to 80 degrees. Flighting 54 is angled with respect to transverse lip 26 at an angle FA. Auger 14 is driven by shaft 46 which is turned by a motor 48. Shaft 46 runs through the length of auger 14 and passes through an opening therefor in end plate 30 and into a bearing housing 50 mounted on end plate 30 and which supports shaft 46 for rotation therein in a well known manner. Auger 14 rotates in the direction of arrow 64 which is counterclockwise as seen in FIGS. 2, 3, 8 and 9. As auger 14 rotates, the helical flighting pushes material along channel 10 in the direction of arrow 65 and over lip 26 as depicted in FIGS. 4A, 4B, 5A and 5B. The rate of rotation of auger 14 therefore determines the rate at which material is dispensed from opening 16. Approximately one pitch of the auger flighting extends beyond lip 26 and is disposed above opening 16.
The improvement of the present invention comprises a flow plate 66 which, as best seen in FIGS. 2 and 10-12, includes a sheet portion 67 and a rod 68. Flow plate 66 is pivotally mounted on channel 10 and is moveable between a first, or use, position in which sheet portion 67 extends laterally across a portion of opening 16 and is aligned with and forms a partial extension of channel 10 as seen in FIGS. 2, 6 and 8, and a second or non-use position wherein sheet portion 67 is disposed generally vertically and adjacent one of the side walls providing opening 16 substantially out of the way of the material being dispensed across lip 26 of channel 10, as seen in FIGS. 3, 7 and 9. Flow plate 66 is pivotally supported by rod 68 which is attached along one edge of sheet portion 67 such as by welding. The rod has a first end 70 pivotally mounted in opening 36 in end plate 30 and a second end 72 pivotally mounted in an opening 74 in a support wall 76 extending laterally outwardly from the corresponding side wall 20 of channel 10. While support wall 76 is shown attached to a side wall 20 of the channel, it could also be formed as part of truck T or as part of the hopper H depending on the configuration of the spreader. Rod 68 is free to rotate in openings 36 and 74 and thus sheet portion 67 of flow plate 66 is pivotable about the axis of rod 68 and which axis is generally parallel to auger axis A.
Sheet portion 67 includes an axially inner edge 78, an axially outer edge 80, a laterally inner angled side edge 82 and a laterally outer side edge 84 to which rod 68 is welded. Side edge 82 is angled with respect to flighting 54 at an angle BA. Sheet portion 67 is preferably formed from 7 gauge sheet steel but may be formed from any suitable material which can stand up to abrasive and/or corrosive conditions associated with the spreading of salt or sand. Sheet portion 67 could be evenly curved to conform to the contour of channel 10, but in the preferred embodiment is comprised of a plurality of planar sections which meet at angles which makes the plate easy to manufacture. Specifically, as best seen in FIGS. 10 and 11, sheet portion 67 is trapezoidal in peripheral contour and includes a plurality of bends parallel to rod 68 which separate sheet portion 67 into a plurality of laterally adjacent generally planar sections. A first section 86 is rectangular and is defined by edges 78, 80 and 84 and a first bend 88 parallel to edge 84; a second section 92 is also rectangular and is defined by edges 78 and 80, first bend 88, and a second bend 92 parallel to first bend 88; a third section 94 is pentagonal and is defined by edges 78, 80 and 82, second bend 92, and a third bend 96 parallel to bend 92; a fourth section 98 is quadrilateral and defined by edges 78 and 82, third bend 96, and a fourth bend 100 parallel to bend 96; and a fifth section 102 is triangular and defined by inner edges 78 and 82 and fourth bend 100. The angle between the plane of first section 86 and the plane of fifth section 102 is approximately 70 to 90 degrees and preferably around 80 degrees. The bend between each section is approximately 20 degrees which results in plate portion 67 being generally aligned with bottom 22 of channel 10 over about an 80 degree arc when the flow plate is in the first position shown in FIG. 8. Rod 68 is mounted slightly higher than axis A of shaft 46 and the bends in plate portion 67 cause flow plate 66 to conform approximately to the curvature of channel bottom 22. As can be seen in FIG. 8, plate portion 67 extends laterally across approximately 2/3 of the arcuate extent of channel bottom 22. Third section 94 is disposed partially beneath auger sleeve 52, fourth section 98 is disposed beneath sleeve 52 and shaft 46 and is approximately horizontal, and fifth section 102 is partially disposed beneath sleeve 52.
Flow plate 66 is movable between a first or use position underlying and aligned with channel 10 as shown in FIGS. 2, 6 and 8 and a second non-use position in which it depends from and is positioned to one side of channel 10 as shown in FIGS. 3, 7 and 9. Displacement of flow plate 66 between the two positions is achieved through a control arm 104 pivotally attached to the underside of plate portion 67 between bend 88 and bend 92 by a pair of spaced apart brackets 106 and 108 welded to plate section 90. Arm 104 has a first end portion 112, a central portion 114 and a second end portion 116 all of which have a circular cross-section. Central portion 114 passes through brackets 106 and 108 and is loosely supported therein so that portion 114 can rotate within the brackets and also slide back and forth therein in a direction parallel to that of rod 68. End portions 112 and 116 join central portion 114 at right angles and prevent arm 104 from sliding out of brackets 106 and 108. In the use position of flow plate 66 shown in FIG. 2, end 112 extends through slot 32 and downwardly along the outer side of wall 30 to releasably hold the flow plate in its use position. By turning control member 104 through the use of end 116, end 112 can be aligned with slot 32 and withdrawn therethrough to release flow plate 66 for pivotal movement to its non-use position shown in FIG. 3. At the latter position, the control member is turned to align end 112 with slot 34, is displaced to move end 112 through the slot and is then released for end 112 to extend downwardly along the outer side of wall 30. In this manner, slots 32 and 34 support arm 104 which in turn holds plate 66 steadily in the corresponding one of its use and non-use positions.
The problem overcome in accordance with the subject invention can best be understood by reference to FIGS. 4A, 4B, 5A and 5B which schematically show material M being moved along channel 10 by auger 14. FIGS. 5A and 5B show how the empty spaces between flights cause the material to be dispensed intermittently. This problem is aggravated when material such as wet salt or sand is being dispensed because it tends to fall off of transverse lip 26 and through opening 16 in large clumps C when no flow plate is present. At low auger speeds, this problem is particularly noticeable. The present invention solves these problems by positioning flow plate 66 to extend axially outwardly from lip 26 and by providing the plate with a dispensing or terminal end edge 82 which is angled with respect to axis A at an angle CA and also angled with respect to the pitch angle PA of flight 54. This eliminates the effects of the empty spaces between the flights and also reduces the size of clumps which fall off of end edge 82 when the material being dispensed is damp.
Specifically, end edge 82 is angled with respect to transverse lip 26 and to axis A to reduce or eliminate the time periods during which there is no material being dispensed over the dispensing edge 82. As can be seen in FIG. 4A, there is no material M directly over transverse lip 26. If the flow plate 66 were not present, a pause in the dispensing of material would occur until the material being moved by the next flight arrived at transverse lip 26. However, because flow plate 66 underlies a portion of flighting 54, material continues to be dispensed over dispensing edge 82 even after flighting 54 has passed over transverse lip 26. As material being pushed by a flight nears wall 30, more material being propelled by the following flight begins to drop off of terminal lip 26 and dispensing edge 82. In this manner, the pauses in the dispensing of material are reduced or eliminated. Additionally, because the angle BA between dispensing edge 82 and flighting 54 is much greater than angle FA between the flighting and transverse lip 26, it takes much longer for flighting 54 to pass over edge 82 than to pass over transverse lip 26. This extends the time period over which material is dispensed to even the flow rate thereof. In addition, this configuration allows only small amounts of damp material to overhang the channel end before falling into opening 16. These smaller lumps L are shown in FIG. 4B.
Any angle between transverse lip 26 and dispensing edge 82 will provide some benefit over a dispensing edge transverse to axis A such as transverse lip 26. Ideally, however, the angle will be related to the pitch length P such that there is always a portion of flighting 54 positioned above dispensing edge 82. Angle CA between the dispensing edge and axis A should also be related to the flighting width B to maximize the benefits obtained with this invention. This is best understood in reference to FIG. 10, wherein it is apparent that flow plate 66 includes a triangular portion 69 defined by dispensing edge 82, a line 83 and a first portion 77 of lateral edge 78. Line 83 is approximately equal to pitch length P. Portion 77 of lateral edge 78 should be selected to be approximately equal to one half of auger width B. Because dispensing edge 82 forms the hypotenuse of a right triangle having portion 77 and line 83 as legs, the length of dispensing edge 82 is equal to the square root of (p 2 +(B/2) 2 ). This results in angle CA being equal to arctan B/2A, angle FA between flighting 54 and transverse lip 26 being equal to 90-PA, and angle BA, the acute angle between flighting 54 and dispensing edge 82 being equal to 180(PA+CA). With a standard auger, angle CA is generally in the range of 30 to 35 degrees and preferably about 32 degrees, angle FA is about 15 degrees, and angle BA is about 65 to 70 degrees. While these angles have been found to give optimal results, minor deviations therefrom will not significantly affect the performance of this device.
FIGS. 13 and 14 show a second embodiment of the subject invention wherein identical numerals are used to identify parts common to both embodiments. In this embodiment, flow plate 130 is axially slidably mounted beneath channel 10 for axial movement parallel to channel 10 and auger 14. Flow plate 130 has an axially outer edge 132 and an angled laterally inner side edge 134, which edges are correspond respectively to edges 80 and 82 of flow plate 66 in the first embodiment. Flow plate 130 also includes an axially inner edge 136 spaced from outer edge 132 and a laterally outer side edge 138 extending between edges 132 and 136, and a second laterally inner side edge 140 extending between angled edge 134 and edge 136. This results in a plate identical to plate portion 67 of flow plate 66, except for the rectangular extension provided by edge 140 and a corresponding axial portion of edge 138, and which extension underlies lip 26 of channel 10 when flow plate 130 is in the use position shown in solid lines in FIG. 14. Side edge 138 is slidably mounted in a first slot 142 parallel to channel 10 in a first support 144 attached to channel 10, and side edge 140 is slidably mounted in a second slot 146 parallel to channel 10 in a second support 148 attached beneath channel 10. A control rod 150 which is fixedly secured to the bottom of flow plate 130 such as by welding provides a handle for manually sliding plate 130 axially of channel 10 between the use position and the non-use position shown by broken lines in FIG. 14. When fully extended or fully retracted, flow plate 130 functions like flow plate 66 in its use and non-use positions, respectively.
The present invention has been described in terms of two preferred embodiments which are in no way intended to limit the scope of the present invention. Obvious modifications will become apparent to those skilled in the art upon reading this specification, and all such modifications are intended to comprise a part of this invention to the extent that they are covered by the following claims. | A conveyor for particulate matter is provided with a channel extension movable between a use position aligned with the channel and a non-use position displaced relative to the channel. The extension includes an angled edge which cooperates with the auger flighting to shear material as it leaves the extension to break apart lumps which form in the material and provide an even flow of material from the conveyor. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to fly swatters and devices for capturing small pests, and in particular, devices using an adhesive to capture small pests
[0003] 2. Description of Related Art
[0004] Flying insects, spiders and other small pests are not only annoying but can carry disease, bite, and present other health hazards. Using an insect spray to exterminate these pests may be undesirable inside a home because of concerns with environmental pollution or contamination of foodstuffs.
[0005] House flies can be captured by an adhesive strip that is suspended from the ceiling. This stationary strip can be scented or otherwise impregnated to attract flies. Flies landing on the strip are caught on the adhesive and eventually die. While effective, the sight of several dead flies stuck to an adhesive strip is somewhat repulsive. Moreover, one cannot know in advance where the house fly will appear and suspending multiple strips in every room adds to the unpleasantness and cost of these adhesive strips.
[0006] The well-known fly swatter may have a handle supporting a plastic perforated panel. With this device a user attempts to quickly swat the fly after it lands on a flat surface. Unfortunately, the fly can land behind Venetian blinds, inside a lamp shade or in a crevice of an uneven surface, safe from the swatter. Also, the user may be unable to use the swatter without causing damage if the fly should land on something fragile such as a light fixture.
[0007] See also U.S. Pat. Nos. 834,039; 884,213; 1,005,443; 1,083,179; 1,604,460; 1,718,805; 1,802,774; 2,437,447; 2,618,882; 2,015,092; 3,449,856; 4,120,114; 4,653,222; 4,759,150; 4,787,171; 4,905,408; 4,907,367; 5,269,092; 5,630,290; 6,055,767; 6,067,746; 6,957,510; and 7,165,355.
SUMMARY OF THE INVENTION
[0008] In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a device for capturing small pests. The device has a sheet with an outer side and a panel with a handle. The panel has at least one overhang for holding the sheet in place. The sheet is mounted on the panel. The outer side of the sheet is partially coated with a pest detaining adhesive but is adhesive free in a region located under the overhang.
[0009] According to another aspect of the invention, there is provided a device for capturing small pests. The device includes a sheet having a margin with a marginal recess and an outer side coated at least partially with a pest detaining adhesive. The sheet has a pull tab in the recess that is no longer or wider than the recess. The device also has a panel with a handle and adapted to hold the sheet.
[0010] According to yet another aspect of the invention, there is provided a device for capturing small pests. The device includes a sheet having a separable stack of disposable layers each with pest detaining adhesive applied to at least a portion of an outer side. The layers each have a margin with a marginal recess. Each of the layers has a deflected pull tab in the recess that is no longer or wider than the recess. The device also has a perforated panel with a handle. The panel has a peripheral wall with a first and a second section rising in opposite directions from the panel. The panel has at least one overhang projecting inwardly from the peripheral wall for holding the sheet in place. The sheet is mounted on the panel. The outer side of the sheet is adhesive free in a region located under the overhang. The device has a cover arranged to fit on the panel and at least partially cover the panel. The cover has at least one internal detent for engaging the panel and holding the panel in place.
[0011] Devices of the foregoing type offer a safe and effective way of capturing small pests, avoiding many of the disadvantages and unpleasantness associated with the prior art. In a disclosed embodiment a handle supports a perforated panel that is overlaid with a sheet. The outer side of this sheet has a pest detaining adhesive. Accordingly, the user can use the handle to swing the adhesive sheet to intercept and capture a flying insect. The adhesive sheet can then be removed from the panel, discarded and replaced with a fresh adhesive sheet. In some cases, the outside of the replacement sheet may be covered with a removable protective film that covers the pest detaining adhesive to facilitate handling during installation.
[0012] In a disclosed embodiment the adhesive sheet lies within the borders of a peripheral wall on the panel. The peripheral wall allows the user to lay the device down on a surface without fear of the adhesive sheet sticking to the surface. Also, the device may be simply placed over a crawling insect such as a spider whose escape route is then blocked by the peripheral wall. Eventually this crawling insect will climb the peripheral wall only to be captured on the adhesive.
[0013] In addition, this peripheral wall helps to center the sheet and keep it in position. Also to keep the sheet in place, the peripheral wall may have an inwardly projecting overhang in the form of a tab that hangs over the adhesive sheet. The outside of the adhesive sheet may have adhesive-free regions under the overhanging tabs to avoid sticking to the tabs during sheet removal.
[0014] In some embodiments the peripheral wall can extend in opposite directions from the panel thereby defining bordered regions on opposite sides of the panel that may each contain an adhesive sheet. This doubles the effectiveness of the device, which now can be swung in either direction.
[0015] Moreover, some embodiments may use sheets in the form of a stack of layers each coated with a pest detaining adhesive. The layers may have a removable film to allow easy separation of the layers. Accordingly, stack can be installed on the panel of so that used layers can be easily removed and discarded.
[0016] In a disclosed embodiment the adhesive sheet has a pull tab to facilitate sheet removal. To make the pull tab less obtrusive, it is placed in a recess along the margin of the sheet. To make a pull tab more accessible it is bent or deflected upwardly, making it easier to grab. In embodiments where the sheet is composed of a stack of layers, each of the pull tabs is aligned and deflected upwardly from aligned marginal recesses.
[0017] The disclosed embodiment also employs a cover in the form of a five sided box having an open side into which the panel is inserted. The cover can hide captured insects and also avoid inadvertent touching of or contact with the adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above brief description as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:
[0019] FIG. 1 is a plan view of a device in accordance with principles of the present invention;
[0020] FIG. 2 is a detail, fragmentary view of a portion of the device of FIG. 1 with its sheet removed;
[0021] FIG. 3 is a fragmentary, perspective view of a portion of the panel of FIG. 2 ;
[0022] FIG. 4 is a detailed, fragmentary view of the sheet of FIG. 1 ;
[0023] FIG. 5 is an edge view of the sheet of FIG. 1 ;
[0024] FIG. 6 is a cross-sectional view of a sheet having a stack of layers on a backer, which is an alternate to the sheet shown in FIG. 5 ;
[0025] FIG. 7 is a perspective view of the device of FIG. 1 (a portion of the handle broken away for illustrative purposes) and a cover for covering the panel; and
[0026] FIG. 8 is an end view of the cover of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring to FIGS. 1-3 , the illustrated device has a tapered handle 10 rounded on one end where a hang hole 12 is located. Handle 10 has an H-shaped cross-section. Handle 10 supports a rectangular panel 14 having a perforated deck 16 surrounded on four side by peripheral wall 18 . In some embodiments panel 14 may have an outline that is another polygonal shape, semicircular, round, oval, etc. The joint between handle 10 and panel 16 is reinforced with a pair of triangular reinforcing webs 19 extending between handle 10 and the adjacent portion of wall 18 .
[0028] Deck 16 has a number of perforations 20 generally arranged as concentric arcs separated into four different quadrants, although other embodiments may have a simpler or more complex hole pattern. The perforations are optional but do help reduce weight and material costs.
[0029] Wall 18 has sections 18 A and 18 B rising in opposite directions from deck 16 , although in some embodiments the wall may rise in just one direction. Inwardly projecting from wall 18 A are four overhangs 22 , shown as rounded cantilevered tabs. A complimentary arrangement of four tabs 22 also projects inwardly from wall 18 B. There is clearance between tabs 22 and deck 16 to hold a pair of sheets 24 one on each side of deck 16 .
[0030] The number, placement, dimensions and shape of the tabs 22 may be different in different embodiments. Also, in a given embodiment the tabs need not have the same shape. In embodiments where only a single sheet will be placed on one side of deck 16 , wall 18 will only project in one direction and therefore tabs will be located only on one side of the deck. In some embodiments tabs 22 may be replaced with L-shaped fingers rising from deck 16 . In still other embodiments tabs 22 may be replaced with undercuts at the base of walls 18 A and 18 B. Also, various types of mechanical clips and holding devices may be used in other embodiments as well.
[0031] Referring to FIGS. 1 , 4 and 5 , sheet 24 comprises paper layer 24 A, but other embodiments may employ instead a plastic film, cardboard or other sheet material. Sheet 24 has a rectangular margin 24 D with rounded corners all designed to fit in the boundary of wall 18 . The outer side of sheet 24 will be coated with a pest detaining adhesive 24 C. The inner side 24 B of sheet 24 will be uncoated. Adhesive 24 B will be strong enough to capture pests that land or walk on the adhesive.
[0032] Adhesive 24 C may be the type of adhesives commonly used in commercially available flypaper although any type of adhesive may be used that is strong enough to immediately capture the targeted pest. In this embodiment adhesive 24 C is strong enough to capture flies, wasps, mosquitoes, ants, roaches, spiders, and the like. In some embodiments the adhesive 24 C may be impregnated with a substance that attracts or lures the pest. The substance can emit an odor associated with a food source, an intraspecies signal, etc. In many embodiments the adhesive 24 C will be made washable and with a stickiness that reduces the tendency to stick to furniture, clothing, etc.
[0033] The regions 26 of sheet 24 under overhangs 22 are adhesive free to prevent sheet 24 from sticking to the overhangs.
[0034] Another adhesive free region 28 is associated with pull tab 30 , which is located in marginal recess 32 . Eliminating adhesive in the region 28 allows a user to grasp pull tab 30 without the mess of touching the adhesive. Tab 30 is shown with rounded corners and may be about 318 inch (10 mm) long and ¼ inch (6 mm) wide although other dimensions and shapes may be employed in other embodiments.
[0035] Pull tab 30 does not extend beyond marginal recess 32 to simplify the overall shape of sheet 24 and to avoid interfering with wall 18 . In fact, pull tab 30 is recessed slightly from margin 24 D by for example 1/16 inch (1.6 mm). Also, in this embodiment tab 30 is deflected or curled so its distal end has a higher elevation than margin 24 D, making the tab easier to grasp.
[0036] Sheet 24 has an optional removable covering 25 made of a substance (or impregnated or coated) in order to avoid sticking to adhesive 24 C. Covering 25 can protect and preserve adhesive 24 C, avoid unnecessary finger contact, and allow similar sheets to be stacked without sticking together.
[0037] Referring to FIG. 6 , the illustrated sheet 224 replaces the previously described sheet (sheet 24 of FIG. 5 ) with a stack of disposable layers 124 (seven layers in this exemplary embodiment). Each of the layers 124 will be paper that is coated on one side with a pest detaining adhesive (the same adhesive 24 C illustrated in FIG. 5 ). Again, instead of paper, the layer 124 may employ a plastic film, cardboard or other sheet material. This adhesive coating will be formulated to allow easy separation of the individual layers 124 when used in a manner to be described presently. Also in some embodiments, a single removable cover (similar to cover 25 of FIG. 5 ) may be placed atop the uppermost layer 124 A to allow easy handling and to allow similar stacks to be bundled without sticking together.
[0038] In this embodiment, the underside of the lowermost layer 124 B is attached to a backer 134 made of a thicker material, for example, cardboard. The separable stack of disposable layers 124 and backer 134 may have the same outline as the previously mentioned sheet (sheet 24 of FIG. 1 ). In particular, pull tabs 130 may have the same outline and may be located in a marginal recess. Also as before, pull tabs 130 are deflected or curled so that their distal ends have a higher elevation, making them easier to grasp. Tabs 130 are shown herein deflected about 30°, although other manners and degrees of deflection are contemplated.
[0039] Referring to FIGS. 7 and 8 , cover 36 is a hollow five-sided rectangular case having an open side for receiving panel 14 . Cover 36 is sized slightly larger than panel 14 and has two pairs of opposing internal detents 38 . Detents 38 are shown in this embodiment as round nubs protruding from the inner surfaces of the larger opposing sides of cover 36 . Detents 38 are offset from the closed end of cover 36 a distance slightly greater than the thickness of wall sections 18 A and 18 B to allow the detents to ride over and snap around the wall sections. Instead of dome-shaped detents, in some embodiments the detents may be eliminated or replaced with alternate detents such as spring clips.
[0040] Instead of a five sided case, the disclosed cover can be a clamshell design with six sides and a hole for the handle. In some cases the cover may be five sided with a hole on one side so the cover can be slipped over the handle 10 and slid over the panel 14 . In this latter embodiment, the cover may be a secured to a vertical surface and then used as a holster for the device.
[0041] To facilitate an understanding of the principles associated with the foregoing apparatus, its operation will be briefly described in conjunction with FIGS. 1 through 8 . Sheet 24 is placed inside wall 18 on one side of panel 14 with pull tab 30 adjacent handle 10 (although sheet 24 could in fact be rotated 180°, or for square sheets ±90°). In particular, opposite edges of sheet 24 are inserted under overhangs 22 by bowing the sheet slightly and releasing it. Sheet 24 may alternatively be inserted under overhangs 22 by angling the edge of sheet 24 opposite pull tab 30 under the pair of overhangs closest to handle 10 . Sheet 24 is then slid upward toward the end of panel 14 opposite handle 10 . Sheet 24 is lightly pressed against deck 16 as it is slid to ensure that the edge of sheet 24 opposite pull tab 30 slides between deck 16 and the pair of overhangs 22 located furthest from handle 10 .
[0042] An additional sheet (not shown) is similarly inserted on the opposite side of panel 14 . The protective covers 25 are then removed from both sheets 24 exposing the pest detaining adhesive 24 C, although some users may prefer to remove covers 25 before installing sheets 24 onto panel 14 .
[0043] A user may grasp handle 10 and swing panel 14 toward insects flying nearby. Insects impacting sheet 24 are captured on the pest detaining adhesive 24 C. In some cases, panel 14 may be placed over a small pest on a surface so that peripheral wall 18 A (or 18 B) and sheet 24 form a cage containing the pest (not necessarily an insect but some other small pest, such as a spider). Panel 14 is held in place until the pest moves about and becomes stuck on the pest detaining adhesive 24 C. Moreover, panel 14 may be slid while pressing wall 18 A down, in order to agitate the pest and cause it to move into contact with the adhesive 24 C.
[0044] In some cases a flying insect may land on an uneven or fragile surface where the panel 14 may not be placed effectively or safely. In this case, the user may simply quickly bring the panel 14 nearby and the insect may still contact adhesive 24 C and be captured anyway.
[0045] When not in use, the device may be placed upon a level surface with wall section 18 A (or 18 B) resting on the surface. Advantageously, wall 18 elevates sheet 24 and its adhesive 24 C to avoid contact with the resting surface. Also, if captured pests are on only one side, they can be positioned facing down and therefore hidden from view.
[0046] When the user is finished catching insects, panel 14 may be inserted in cover 36 for storage. Panel 14 is inserted into the open end of cover 36 until the edges of walls 18 A and 18 B contact detents 38 . The user continues to push panel into cover 36 causing detents 38 to snap over wall 18 . Wall 18 is retained between the closed end of cover 36 and detents 38 . Thus positioned, cover 36 thereby conceals the pests trapped on sheet 24 and shield the adhesive 24 C. A user may later grasp and pull handle 10 away from cover 36 when the device is to be used again.
[0047] With the cover 36 removed, a user may remove sheet 24 by grasping pull tab 30 and lifting sheet 24 away from deck 16 and then pulling toward handle 10 until the edge of sheet 24 opposite pull tab 30 clears overhangs 22 . Sheet 24 may also be removed from panel 14 by grasping pull tab 30 and pulling perpendicular to deck 16 until the edges of sheet 24 clear overhangs 22 . The used sheet may then be discarded and replaced with a new sheet using one of the methods previously described.
[0048] The multilayered sheet 224 of FIG. 5 may also be placed on each side of panel 14 instead of sheet 24 . The insertion of sheet 224 is similar to that of sheet 24 previously described. When the user wants to expose a fresh layer of adhesive, the uppermost layer 124 A may be removed by grasping its pull tab 130 and peeling it away from the sheet located directly beneath it. Layers 124 may be removed from the stack as necessary until the last layer 124 B is used. At this time, the user may remove the last layer 124 B together with backer 134 and install a new separable stack 224 as previously described.
[0049] It is appreciated that various modifications may be implemented with respect to the above described embodiments. For example, the pull tabs may extend beyond the margin of the sheet and may also bend outwardly to allow easy grasping. In some embodiments the single optional pull tab can be replaced with multiple pull tabs at different positions on the same sheet. For embodiments having multiple separable layers, the pull tabs may be located at different spaced positions for each layer. In some cases the overhangs may be replaced with a snap-in ring for holding the sheet in place. Alternatively, the underside of the sheet may have a light adhesive coating for temporarily holding the sheet onto the panel. In addition, different type of types of sheets may be placed on opposite sides of the panel so that one side may target large flying insects while the other side targets small spiders. Moreover, the two oppositely projecting wall sections may have different heights to accommodate different size pests. In fact, in some embodiments there may be no wall projecting from one side even though an adhesive sheet is placed on that side.
[0050] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A device can capture small pests with a sheet overlaying a perforated panel. The sheet may be one layer or several separable and disposable layers with pest detaining adhesive applied to at least a portion of an outer side. The sheet has a marginal recess with a deflected pull tab that is no longer or wider than the recess. The perforated panel has a handle and a peripheral wall with a first and a second section rising in opposite directions from the panel. The panel has at least one overhang projecting inwardly from the peripheral wall for holding the sheet in place. The outer side of said sheet is adhesive free in a region located under the overhang. A cover can fit on the panel and at least partially cover it. The cover has at least one internal detent for engaging the panel and holding it in place. | 0 |
FIELD OF THE INVENTION
The field of this invention lies within the horse racing art. In particular, it lies within the art of guardrails for horses on tracks that can be dirt tracks used for thoroughbred racing. It also lies within the area of horse racing that utilizes rails for protection of racers in sulky racing. In addition thereto, it addresses the field of horse racing on grass, where grass tracks are utilized with protective railings.
THE PRIOR ART
The prior art of rails for horse racing involves generally fixed rails. The rails extend around the inside of the track. They are usually comprised of a stanchion or post. The stanchions or posts are curved and support a rail which extends around the inside of the track. This rail is the rail which guides the horses and the riders around the extent of the track.
Recently, the inventor hereof has substantially improved the state of the art by providing a rail with a substantial safety feature. The safety feature is in the form of a series of elongated protective panels. The elongated protective panels extend between the posts on the rail and serve to cover the post and rail.
The foregoing post and rail covering can be exemplified by the inventor's U.S. Pat. No. 4,443,002, issued Apr. 17, 1984. It can be seen therein that the inventor has invented an elongated series of panels that are shaped to fit over the stanchions or posts and rail. This serves to protect the riders and horses from falling into the stanchions or the curved portion thereof and becoming severely injured.
The foregoing invention was an advance over the art cited therein, including the U.S. patents incorporated herein by reference as prior art that were cited in that patent.
This invention directs itself to not only a protective rail and stanchion or post configuration, but the convertibility of such tracks equipped therewith and with a standard post and rail to other types of tracks. In particular, it addresses itself to the utilization of the posts and rails of a regular track in conjunction with a second system for providing sulky racing.
In the past, sulky racing has had to use a particular type of rail different from the type used for regular horse racing. This, of course, presented problems with regard to changing one track rail to another.
There have also been attempts at changing the track rail of a standard racehorse track to another. Such activities have not met with a great degree of success. Generally, the tracks have to be such wherein they incorporate two different types of rails, or two different types of tracks have to be established. Also, existing art demands that one particular rail be removed or be supplemented with another in an incompatible manner in order to provide horse racing and sulky racing on the same track.
This invention is directed toward allowing for convertiblity of a standard racetrack into a sulky racetrack by merely lowering an arm that is pivoted on a pair of support brackets. The arm moves upwardly and downwardly on the post underneath the rail and protective cover. At the end of the arm is a semicircular collar with splines and channels on the edge regions thereof. The splines and channels on the edge regions receive a second semicircular collar thereover in relationship therewith in order to hold a rail. The rail can be in the form of pipes or rails that extend into the two semicircular collars in mated abutting relationship.
When the semicircular collars have been implaced, they hold the pipe or rail with the arm and the depending brackets holding the arm outwardly. The entire structure can then be used as a sulky guide rail extending from a standard horse racing rail. This is an advance over the art, inasmuch as it can be used at any particular time by merely lowering the arm and inserting the pipes into the collars which form the rail around the length of the track.
In addition to the foregoing, there has been a form of grass track horse racing over the years. The grass track racing has generally incorporated rails that can be moved to avoid wearing the turf in one spot. Also, there are portable fences that have significant moving costs attendant therewith, in order to move them into different areas on a grass track.
It is oftentimes customary to have a grass track with portable rails moved to different locations in order to prevent the turf of the grass track from being unduly trod upon in one particular location on a constant basis. This is accomplished by means of moving the rail inwardly and outwardly around the track and providing for different locations on the grass.
During the movement of such rails and fencing, it becomes a complex situation to disassemble the rails, move them and set them up again. This invention overcomes the foregoing complexity by providing movable stakes which can be pounded into the ground and are such that they support a series of pipes or rail tubing on the stanchions or posts. The grass track rail tubing is supported in the same manner as the prior described sulky tubing on the stanchions or posts. This is accomplished by having a semicircular collar attached to a stanchion. A second semicircular collar fits over the first collar and receives pipe rail therein in order to form a completed rail for a grass track.
The stanchions are supported on the stakes which are driven into the ground. The stakes have a specific configuration to prevent the discoloring of grass thereunder so that horses are not frightened by seeing whitened spots or dead spots of grass when they are racing in an area which had previously had stakes driven thereunder.
As a consequence, this invention not only provides for portability and movement of grass tracks but also enhancement of regular tracks for sulky racing. As a consequence, it is a substantial improvement over the art and as will be seen in the following specification, has a significant degree of patentability attendant therewith.
SUMMARY OF THE INVENTION
In summation, this invention comprises an improved horse racing rail that can be used interchangeably for thoroughbred track racing, sulky racing, and incorporates interchangeable elements for grass track racing.
More particularly, it incorporates a post or stanchion that is a normal horse racing stanchion that supports a rail around the inside of a track. The stanchion and rail can be optionally covered by a safety panel that is known in the prior art through the development of the inventor hereof.
Extending from the stanchion or post is a pivotal arm. The pivotal arm can swing from the upper inside portion of the stanchion or post at the curved portion thereof downwardly and be supported by two pivotal brackets. The arm supports a first semicircular collar. The first semicircular collar on the arm receives a second semicircular collar thereover. Between the two semicircular collars, a section of pipe or rounded rail can be inserted. This pipe or rounded rail is secured therein and serves to provide a rail on the inside of the track at a lowered area for sulky racing. The sulky rail and support when not in use is removed and the arm is swung upwardly into the underportion of the optional panel and the stanchion. This provides for disposal or stowing of the sulky rail support so that the upper rail of the track can then be used for normal racing purposes.
The combination of the two respective semicircular collars can be utilized in conjunction with a stanchion supported on a stake. The same tubular or circular pipe or rail can be fitted into the semicircular collars and held by the stanchions. This effectively provides for a support thereof on the stake so as to avoid duplication of rails between grass track racing and sulky racing. In addition thereto, the stake can be moved on a grass track that supports the stanchions and rails in an effective manner to avoid undue wear on the grass track.
Thus, the entire invention can be used with the interchangeable parts hereof to provide normal horse racing, sulky racing, and grass track racing in an easy and facile manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood by reference to the description below taken in conjunction with the accompanying drawings wherein:
FIG. 1 shows a perspective view of a racetrack rail of this invention incorporating the sulky rail supported on the pivotal arm with the semicircular collars and the tubing or rail within the sulky rail support.
FIG. 2 shows a side elevation view that has been sectioned and a portion of the semicircular rail support collar has been shown in removed orientation for explanatory purposes.
FIG. 3 shows a sectional view as fragmented in the direction of lines 3--3 of FIG. 1 of the semicircular collar connection means for the sulky rail of this invention.
FIG. 4 shows a sectional and fragmented view of the detail of the semicircular coupling means for the sulky rail as sectioned through the midline of the showing of FIG. 3.
FIG. 5 shows a view of the sulky rail and pivotal support arm when it is not in use and folded up under the stanchion or posts.
FIG. 6 shows a view of the sulky rail semicircular collars that support and surround the elongated pipe or rail with the top semicircular collar covering the rail and being implaced therein with the pipe or sulky rail.
FIG. 7 shows a fragmented view of the stanchion and pipe support of this invention for grass track racing.
FIG. 8 shows a view of the stanchion and support with the rail in place for grass track racing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a perspective view of a section of the protective racetrack rail of this inventon that incorporates the sulky racetrack rail therewith. Looking more particularly at FIG. 1, it can be seen that a stanchion 10 or post has been shown implaced within the ground 12. The stanchion 10 or post can be implaced in any particular manner, such as being driven into the ground on a permanent basis or set in concrete or other permanent means. It can also be implaced in the ground 12 by a temporary securement, such as a post or fitting, over which the stanchion 10 is set or secured to such as that exemplified in FIGS. 7 and 8.
The stanchion 10 curves upwardly in a generally curved section 14 into an angularly bent portion 16 that can be seen more specifically in FIG. 5 and FIG. 2. This upwardly extending angular portion 16 can be in any particular configuration. It is not necessary that it angularly extend in the manner shown or the bend 14 in the stanchion be incorporated in the foregoing manner. In effect, the stanchion 10 can be bent with a double gooseneck, or bent in a multitude of sections or curved continually in any manner to allow for the bending over for implacement of a rail at the end thereof.
Looking more particularly at the figures, it can be seen that a rail 18 is shown. The rail 18 has an L shaped hollow cross section with a space 20 within the L shaped cross section. The rail 18 is formed from an extrusion of aluminum or any other suitable material. Extending from the upright portion of the L, is a flange or ledge 22. This flange or ledge 22 creates a space 24 between it and the lateral portion of the L shaped member.
The rail 18 can be substituted by any other suitable rail. In the prior art, it has been known that rails made of wood have been utilized, such as in the inventor's prior patent. Thus, it is readily seen that wood and metal rails of all types and other configurations can be used to provide the rail function of rail 18. Furthermore, a plastic rail can be utilized formed of any particular material attached to the post or stanchions 10 in any particular manner.
The rail 18 with the flattened ledge or flange 22 supports a panel 28. The panel 28 is shown having an upper surface with a plurality of diagonal guides 30. The diagonal guides 30 are raised bosses or strips on the surface of the panel 28. The raised bosses or strips on the surface of the panel 28 provide for channels 32 between the guides 30. The purpose of the guides 30 is to guide an object over the surface thereof angularly out into the field when impact takes place. It is felt that the guides 30 with the channels 32 therebetween tend to guide a rider or horse or other object when impacting the panel in the direction of the infield of the track.
Each panel 28 is formed in a section so that it spans the respective space between the stanchions 10. The panel 28 in this particular instance is shown as a panel with a joindure lip 36. The joindure lip allows for the insertion of an adjacent panel next to it in mating configuration, so that it fits between the space of the joindure lip 36 and the top of the ledge or flange 22. The joindure lip 36 can be in the form of any suitable expansion or offset ledge allowing for a mating panel member to be slid thereunder. Each panel member has a lip or ledge 36 at one end thereof, to allow for an adjacent panel to be slid thereunder or be mated therewith.
The panel 28 is comprised of an L shaped member formed of a plastic. The L shaped member has one portion in the form of a lateral portion 38 which terminates in an upright portion 40. Between the lateral portion 38 and upright portion 40 is an angular corner section 42. The angular corner section 42 provides rigidity and reinforcement as well as a more resilient surface when an impact takes place. The panel in the form of the upright portion 40 terminates in a turned back end 44 and has a reinforcing boss or ridge 46 therein. The panel 44 at the end thereof is attached to the post or stanchion 10 by means of a connector 48. The connector can be in the form of any suitable connection means for securement such as bolts, metal screws, adhesives, plastic connectors, rivets, or any other suitable fastening menas.
Beneath the panel 28 is a railing assembly 54. The railing assembly 54 swings down on a pivotal arm 56. The pivotal arm 56 is comprised of a channel arm member 58 having a channel conformation or groove 60 between two upright walls 61 and 63, and a bottom portion 62. The bottom portion 62 and the upright walls serve to form a U shaped channel.
The U shaped channel forming the arm 56 is pivotally connected by means of a bolt 64 to the stanchion 10. The bolt 64 can be substituted by means of a rivet, plastic snap connector, screw, rod, or any other suitable means for allowing the arm 56 to be pivoted on the stanchion 10. In order to enhance the pivoting, a cutout portion of the base 62 is provided so that the ends of the walls forming the U shaped member can be attached by the bolt or rod 64 to the stanchion 10.
The specific configuration of the pivotal arm 56 allows for the arm to be dropped down from beneath the panel. In order to support and guide the arm, two sets of brackets are utilized. The brackets are pivotal securement or holding brackets 70 and 72. The holding brackets 70 and 72 each comprise a lower portion 74 connected to an upper portion 76. They are interconnected by means of a pin, bolt or rivet 78. The upper portion or upper arm 76 of the bracket is connected to the angular portion 16 of the stanchion 10 by means of a bolt, rod or screw 80 that allows the upper arm 76 of the bracket to pivot therearound. The lower arm portion of the bracket 74 is connected to the pivotal arm 56 by means of a bolt, rod or screw 82 passing from the lower portion 74 through the upright walls 61 and 63 on either side of the arm 56.
The foreoging configuration permits the arm 56 to be raised and lowered by any suitable means to allow for positioning of the pivotal arm 56 in a generally outstretched manner from the stanchion 10. This outstretched manner is generally shown as effectuating a horizontal relationship normal to the upright portion of the stanchion 10. However, as can be appreciated, any particular angular configuration of the positioning of the arm 56, which is sufficient to provide the functions hereof, can be used. It is not necessary to position it in a horizontal manner, or in the normal manner from the stanchion 10.
The arm 56 serves to support a lower first or semicircular collar 90. The collar 90 is formed in a manner so that it has an offset flange or L shaped ridge 92 and a channel member 94. The channel member 94 is provided along the edge of the collar 90 and forms an interior opening thereof having an interior channel surface matching the ridge or flange 92. The interior opening can be seen more clearly in FIG. 5 wherein the channel member 94 can be seen with an opening or passage between the channel walls. The channel member 94 is formed with a hooklike portion 98 which bends backwardly and inwardly to provide the groove or opening 96 in the channel member 94. The foregoing is fundamentally the reciprocal of the flange 92 that can be seen so that it can be formed and mated within the opening 96. In this manner, it can receive a like semicircular collar 100 slipped into relationship therewith, so as to be mated and provide a complete encapsulation of a member between both collars.
As can be seen, a semicircular collar 100 is shown having a channel member 102 analogous to channel member 94 and a flange 104 analogous to flange 92. The foregoing respective flanges and channels mate with each other and are reciprocal so that one can be used as a bottom portion or the top portion respectively, enabling easy and facile manufacture of the entire rail assembly. The two parts are formed from one aluminum extrusion, enabling one part to serve both functions. Any particular flange, channel, chamfer, receipt, lock fitting, cam lock, buckle, hinge, snapover arrangement or other means can be used in order to provide the holding of the two respective semicircular collars. Furthermore, any means can be utlized to function in place of the semicircular collars in generally analogous relationship for holding the rail, as will be described hereinafter.
Looking more particularly at FIG. 3, it can be seen wherein the collars 90 and 100 have been assembled. The lower collar 90 is welded or attached by any suitable means to the arm 56, so that it supports it. The overlying collar 100 is slid into place by means of matching the channel portion 102 to the flange 92 and the flange 104 within the channel member 94. They are slid together in the foregoing manner as can be seen within FIG. 6 whereby they come together in a mating manner in order to hold the rails, as will be detailed hereinafter.
Looking more particularly at the rails, it can be seen that tubular pipelike portions 110 are shown. These tubular pipelike portions 110 roughly correspond to the same distance as the panels 28 and span the area between the stanchions 10. They are inserted in generally abutted relationship as can be seen in FIG. 3. The abutted relationship provides for an implacement of the rail formed of the pipe 110. The rail formed of the pipe 110 allows for continuity and configurative rail patterns all the way around the track at a height lower than the upper rail 18. Thus, it accommodates sulky races on a track.
The configuration of the collars 100 and 90 can be of any suitable configuration generally matching the rail 110 formed of the pipe. Thus, if the pipe that forms the rail is square, ogive, semicircular, or of any other cross section, the collar 90 and 100 should match the cross section in order to accommodate and allow for the holding thereof in juxtaposition to the interior dimension within the collars 90 and 100. Thus, the inside configuration and dimensions of the collar should generally be configured to conform to the pipe or rail outside configurations and dimensions in order to allow them to seat therein.
In order to allow for a smooth transition area between the pipe 110 and the collars 90 and 100, two O rings 120 and 122 are utilized. The O rings 120 and 122 are such wherein they allow for a smooth and elastomeric transition as far as the step or ledge goes between the outside dimensions of the collars 90 and 100 and the pipes 110. Thus, they provide somewhat of a protected surface. Any form of ring, collar, plastic clip, flange, or spline can be utilized in place of the O rings 120 and 122, the thought being that they should provide for less tearing and destructiveness of any object bumping into the interface of the collars 90 and 100 and the pipe 110. Also, the collars 90 and 100 can have a chamfered edge, rather than having the covering. They can taper and fair downwardly circumferentially or have a fillet toward the pipe 110 or have any other conformation which allows for a smooth transition between the two respective portions of the collars and pipe.
In order to hold the collars together, a pin, such as a cotter pin 124 is shown. The pin has a protuberance 126 which allows it to be implaced within an opening 128 of the collar members 92, 94 and 102 and 104. This opening can be seen as an opening 130 into which the pin 124 passes into the opening of the flange and channel of the collar. Thus, the collars 90 and 100 are attached to each other on a removable basis and can be held so that they do not slide backwardly and forwardly by virtue of the relationship of the pin 12 holding them against longitudinal movement with respect to each other. Any particular type of attachment can be utilized in order to secure the collars together in overlying relationship. Suffice it to say, one should not slide with respect to the other.
The lower collar 90 has been shown welded or affixed to the arm 56 by means of a weldment. However, any other suitable attachment can be utilized whereby the weldment 91 can be substituted by an overlaying fit, notches, mating grooves, splines, bolts, rivets, or other means securing the collar 90 to the arm 56.
Looking more particularly at FIGS. 7 and 8, it can be seen that another stanchion 200 is shown with a bend 202 terminating in an upper angular portion 204. The upper angular portion 204 receives a collar portion such as the lower collar 90. The upper collar portion 100 is shown overlying the lower collar portion 90 and can be implaced in the same manner as the prior embodiments. In this manner, the channel member 94 and flange 92 can receive the upper channel 102 and flange 104. Also, the pin 124 that is used to secure the previous upper collar member 100 to the lower collar member 90, can be utilized.
The weldment 91 welding the lower collar 90 to the arm, can be utilized to weld the lower collar to the angular portion 204, or any other suitable connection means can be utilized. Suffice it to say, the interchangeability of parts between the two respective collars 90 and 100 is analogous to the previous utilization whereby each respective channel or collar member was formed so that the reverse thereof allows it to be such wherein it engages the other channel member or collar.
Various configurations can be utilized in the way of cross sectional configurations of the collar in order to meet any outside cross sectional dimensional aspects of the pipe 110 or rail that is used. In this particular case, the pipe 110 has been shown as the rail seated within the upper and lower collar members 100 and 90. Also, the utilization of the O rings 120 and 122 are shown covering the ends of the upper and lower collars 100 and 90. However, the fairing, filleting or chamfering as in the prior embodiment, can be substituted for the O rings.
In order to mount the stanchion or post 200, a stake is shown, namely, a stake 210 is shown having a narrow rod portion 212 implanted in the ground 214. The stake 210 with the rod portion 212 has an outer pipe member 218 having an upper belled flange 220 and a lower belled flange 222. The belled-out portions terminate in shoulders 224 and 226. Each of the belled-out portions has a space respectively in the upper portion 230 and the lower portion 232 which allow the rod 212 to pass therethrough in spaced relationship. This spaced relationship is important as will be seen hereinafter.
The rod portion 212 is driven into the ground during grass racing. It can be used as a portable implacement for the stanchion 200 and effectively allows for the movable location of the track over a grass track area into various locations. Thus, the grass track can be implaced or located in any particular grass area and the stanchions 200 holding the rail 110 can be used in various locations. The only requirement is that the rod 212 forming the stake 210 be driven into the ground at a suitable location.
When the stake 210 is driven into the ground, the lower flange or bell portion 222 seats against the grass and allows the space 232 to permit the grass to grow up therein in a limited manner. This prevents the grass from being completely killed in that particular area to a significant degree. The killing of the grass would be more prominent if the space 232 were not utilized. Thus, the appearance of brown spots when the rail is moved is avoided in some measure. This is important on grass track racing, inasmuch as it can be a deterrent to horse racing because horses sometimes shy from spots on the ground.
The stake 210 can be moved at will to any particular location so as to allow the stanchion 200 to be moved with the rail support providing support for rails or pipes 110. This movement of the stanchion 200 is easily accomplished by merely lifting it over the bell portions 220 and 222 of the stake 210. The outer dimensions of the bell portions 220 and 222 generally conform to the inner dimensions of the stanchion such that the stanchion 200 can slip thereover. The stanchion should fit tightly over the bell portions 200 and 222, so as to not allow it to slip and move in a sloppy manner. However, there should be suitable clearance in order to pass the stanchion 200 thereover and withdraw it from the stake 210 when desired.
The foregong configuration allows for multiple uses of the pipe or other configuration of rail 110 forming the rail by being utilized for grass track and regular track uses with sulky racing. Furthermore, as can be seen, the interchangeability of the collars 90 and 100 provides for utilization of the collars and securement means between various tracks for both grass racing and for sulky racing and regular tracks. Thus, the entire interchangeability of the system allows for portabilty of race track rails on grass tracks, as well as accommodating sulky racing by lowering an arm 56 with the collars 90 and 100 for receipt of rails or pipes 110 to provide for the railings of a track. Additionally, it can be appreciated that various savings are accommodated in the manufacture, as well as the interchangeability of parts for the entire grass track and regular track racing.
When the arm 56 of the regular track is not in use, it can be tucked up under the panel 28 in any suitble manner such that a clip, such as clip 97, or other suitable spring means can be utilized to allow for the folding of the arm 56 upwardly. Also, a securement pin, bolt, latch, or screw can be utilized or any other means for holding the arm 56 upwardly against the bottom of the rail 18.
As can be appreciated, this invention has substantial utilization over the prior art in providing utility to rails for horse racing on both a regular track providing a rail that can be moved for a sulky race into position from a regular rail as well as providing interchangeability of the sulky rail with a grass track rail and other types of rail that are utilized with portable stanchions and stakes for holding the stanchions. As a consequence, this invention should be read broadly over the prior art. | A racetrack convertible guardrail is disclosed herein which includes a plurality of spaced apart upright curved posts or stanchions. The curved posts or stanchions serve to support a racetrack rail which can be formed of metal or wood. Overlying the rail and the stanchions are a continuous number of sheets interfacing with each other to cover the stanchions and the rail for protection of a rider and a horse. Underlying the rail, stanchions and the protective cover is a second rail in the form of tubing or other rail forms supported by a hinged arm that can be utilized for sulky racing. The rail forms are supported by means of collars that are in turn supported by the hinged arm that underlies the stanchion. The collar and the tubing or rail forms can be connected to another form of stanchion that has a stake for supporting the stanchion, rail and tubing with the collars for purposes of grass racing and which can be removed by moving said stake and other components of the rail. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to an electrically controlled valve for fuel injection pumps of motor vehicles.
In a known solenoid valve (EP 0 309 797 B1) which, for controlling the opening area of a connection between a high pressure chamber and a low pressure chamber, has a valve member that is moved by an electromagnet counter to the force of a restoring spring and this valve member is axially guided in a guide bore of the valve housing, the through flow cross section is constituted by the lifting of a conical face, which is disposed on the valve member, up from a conical valve seat in the valve housing, wherein above and below the valve seat, an annular chamber is incorporated into the valve housing into which the high pressure line or the low pressure line respectively feeds. The valve member in the form of a hollow cylinder is connected via a tappet to an armature which is acted upon by the electromagnet. The closing of the through flow cross section between the high and low pressure chamber is carried out when a sealing edge on the valve member, which edge is constituted by the transition of the conical face into the cylindrical jacket face, is set upon the face of the conical valve seat, wherein the through flow cross section between the conical face of the valve member and the valve seat is embodied so that already at the beginning of the opening stroke, as large an opening cross section as possible can be rapidly opened, which steadily grows as the opening stroke progresses further.
The through flow cross section of the known valve has the disadvantage that at the sealing edge and in the through flow cross section between the conical face of the valve member and the valve seat, due to the high flow velocities, the pressure of the fluid falls below the vapor pressure and vapor bubbles or cavities are produced. The valve opens in a delayed fashion due to the pressure drop.
OBJECT AND SUMMARY OF THE INVENTION
The solenoid valve according to the invention has the advantage over the prior art that through the disposition of a deflection point downstream of the sealing edge, throttling, is which can lead to problems in the filling and/or to an undesirable aspiration of the valve needle, does not occur.
The ram pressure on the needle produced by the deflection point considerably increases the force opening the valve so that a rapid and reproducible opening of the valve is assured.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a section through the electrically controlled valve,
FIG. 2 shows the valve seat and valve member in an enlarged scale, and
FIG. 3 is a diagram of the flow progression.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawing shows a partial section through a fuel distributing injection pump of the radial piston pump type. A housing bore 2 in the form of a blind bore or a bore that is closed on one end is let into a housing 1 in this fuel injection pump and a part embodied in the form of a distributor 3 is movably supported in this bore, in rotary fashion in this instance. On its end protruding from the housing bore 2, the distributor 3 has a collar 4 in which cylinder bores 5 are placed, which are radial to the longitudinal axis of the distributor 3 and in which pump pistons 6 are guided, which enclose a common pump working chamber 7 in the inner part of the cylinder bores, which chamber is used as a high pressure source. The pump pistons are driven to reciprocate sliding in a sealed fashion by means of a cam means that is known per se, e.g. by means of a cam ring 8 on which rolling shoes 9 slide, which are connected to the respective pump pistons. The cam ring 8 in this instance is embodied as an essentially stationary cam ring, while the drive of the distributor is carried out via a driving axle 10, which simultaneously produces the relative motion of the rolling shoes along the cam track via the rotary motion of the distributor and is consequently used to drive the pump pistons. In the inward stroke of the pump pistons, a fuel pressure at the level of the fuel injection pressure is generated in the pump working chamber 7. The fuel is conveyed from the pump working chamber 7 via a pressure line 11 in the distributor 3 to an outlet opening in the form of a distributor opening 12 on the jacket face of the distributor. In the region of the mouth of the distributor opening 12 in the jacket face, injection lines 14 that lead from the housing bore 2 are provided in the housing 1 and each lead to a fuel injection valve, not shown in detail, in order to bring the fuel, which has been brought to high pressure, to injection in the internal combustion engine. The high fuel injection pressure is present at the distributor opening 12 per association with the respective fuel injection line 11 only as long as an electrically controlled valve, which controls the injection time and injection quantity and which is, for example, in the form of a solenoid valve 15, is closed with a valve member 16. This solenoid valve is disposed in a connecting line 17 from the distributor opening 12 to a relief chamber 18 connected to the end face of the distributor 3, which chamber is in turn relieved via a relief line 19. When the solenoid valve is open, the fuel displaced out from the pump pistons 6 is consequently returned to the relief chamber 18 in a more or less pressure-free state or one that is at least lower than the fuel injection pressure.
The valve member 16 is disposed in a blind bore 21 coaxial to the rotational axis of the distributor 3, wherein the distributor is simultaneously used as a valve housing. A restoring spring 22 in the form of a helical compression spring acts on the valve member from below and on its end that protrudes into the relief chamber, there is a tappet 24, which is coupled to the armature, not shown, of the electromagnet 25 of the solenoid valve 15. The valve member 16 has a conical sealing face 29, which cooperates with a conical valve seat 32 on the distributor 3, which valve seat 32 connects a high pressure chamber 30 on the distributor opening end to the relief chamber 18.
As can best be seen in the enlarged depiction according to FIG. 2, the conical sealing face 29 of the valve member 16, which sealing face 29 is placed in a sealing manner on the valve seat 32 and thus reliably seals the high pressure chamber 30 in relation to the relief chamber 18, is defined by a downstream edge 33. Downstream of the downstream edge 33 in the through flow direction, a deflection point in the form of an annular deflection wall 34 is formed onto the valve body 3 with a toroid transition at which the flow of the fuel passing through is deflected in the axial direction or in the adjusting direction of the valve body. Opposite this deflection point, downstream of the downstream edge, the valve member 16 is provided with an axially-directed annular face 35, which is defined as an engagement surface or deflector for the fuel passing through.
OPERATION OF THE VALVE
The operation of the device according to the invention will now be explained essentially in conjunction with the diagram of the flow progression according to FIG. 3. The high pressure of approximately 1000 bar prevailing in the high pressure chamber 30 rests against the valve closing member 16 from beneath when the solenoid valve is closed. In order for the solenoid valve 15 to be able to remain closed, it must be pressure balanced and only a slight opening force is permitted to be present in the closed state. The electromagnet 25 is supplied with power and holds the magnet closed.
If the magnetic force is discontinued now by switching off the electromagnet 25, the high pressure, together with the valve spring 22, lifts the valve member 16 up from its valve seat 32. Fluid under high pressure penetrates into a seat gap 35 in an essentially radial direction from the inside toward the outside with a high flow velocity and then reaches the deflection point 34 at which the fluid is deflected in an axial direction. In this through flow direction, it strikes against the annular face 35 on the valve member 16 with full ram pressure. Due to the resulting force, the valve member 16 is thrown open and opens the valve passage in a rapid, complete, and reproducible manner, and the fluid easily reaches into the low pressure chamber 18.
In this manner, an increase of needle opening force that is sought is achieved by a particular utilization of the flow energy by simple means. The solenoid valve 15 must open rapidly in order to achieve a rapid pressure drop at the end of injection in diesel injection pumps controlled by a solenoid valve. The force intensification on the valve member 5 can be arbitrarily altered by varying the size of the annular face 35 and the deflection angle at the deflection point 34. The invention can be generally used, both in distributor injection pumps such as the radial piston distributor injection pump shown above, in unit fuel injectors, line unit fuel injectors, and axial piston pumps.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | An electrically controlled valve which is used for controlling the opening area of a connection between a high pressure chamber and a low pressure chamber. The valve is embodied as a solenoid valve and has a valve seat on which a deflection point is provided downstream of a downstream edge of the valve member in the through flow direction. By means of a flow deflection, the fluid passing through is conveyed against an annular face provided on a valve member. The resulting pressure accelerates the opening of the valve. The solenoid valve is designated for use in fuel injection pumps in motor vehicles. | 5 |
BRIEF DESCRIPTIONS OF THE INVENTION
This invention relates to a quadrupole ion trap and method, and more particularly to an ion trap in which shim electrodes compensate for electric potential faults introduced by apertures drilled into the entrance and exit end caps.
BACKGROUND OF THE INVENTION
An ion trap, in its most common configuration, is composed of a central ring electrode and two end cap electrodes. Other quadrupole ion trap configurations are described in U.S. Pat. No. 5,420,425. Generally, each electrode has a hyperbolic surface facing an internal volume known as the trapping volume. The trapping volume also serves as an analyzing space in which selected ions are retained and sequentially ejected, based upon their mass and charge. It also serves as a reaction volume, in which fragmentation of charged particles is caused by both collisions and interactions with specific fields. When a radio frequency (RF) voltage is applied between the ring and end cap electrodes, a quadrupolar potential is induced within the trapping volume. Generally, each of the end caps has one or more holes drilled into the center for the purpose of introducing ions or electrons into the trapping volume through the entrance end cap and for ejecting ions from the trapping volume to an external detection system through the exit end cap. Ions introduced into or formed within the trapping volume will or will not have stable trajectories, depending upon their mass, charge, the magnitude and frequency of the applied voltages, and the dimensions and geometry of the three electrodes.
Quadrupole ion trap potentials deviate from the ideal quadrupolar potential for two reasons: 1) because of holes drilled into the end caps, and 2) because the shapes of the electrodes have finite values. These effects are referred to as electric potential faults.
The electric potential deviation results in both peak broadening and, in some cases, a shift in measured ion mass from the theoretical mass values. Several schemes have been used and proposed to neutralize electric potential fault effects upon motion of the trapped ions. Franzen et al. U.S. Pat. No. 5,468,958 describes a quadrupole ion trap with switchable multipole fractions, which can be used to correct the electric potential errors due to the finite size of the electrodes.
Electric potential deviations due to the finite size of the trap electrodes are relatively insignificant compared to the deviations caused by the holes used to inject and eject ions. One method for correcting the deviations due to the holes is to stretch the spacing of the end cap electrodes from the ring electrode beyond the theoretical spacing predicted by solving the equations of motion of charged particles contained within the trapping volume
A different approach has been taken by Shimadzu Corporation in U.S. Pat. No. 6,087,658, in which they have mechanically modified the end cap electrodes with a bulge at the internal end of each hole. The stated purpose of the bulge is that it corrects the deviation in the electric potential from the pure quadrupole electric potential by controlling the deviation of the electric potential around the central end cap hole.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a quadrupole ion trap in which electric potential faults are minimized.
There is provided a quadrupole ion trap of the type including a ring electrode and first and second end cap electrodes which define a trapping volume. The end cap electrodes include central apertures for the injection of ions or electrons into the trapping volume and for the ejection of stored ions during analysis of a sample. Electric potential faults in the RF trapping potential are compensated by shim electrodes carried within the central apertures and electrically insulated from the end cap electrodes.
In another embodiment of the invention, there is provided a linear quadrupole ion trap with four electrodes, each divided into one or more sections. One or more apertures are provided for ejection of ions during sample analysis. Electric potential faults in the RF trapping potential are compensated by shim electrodes carried within the apertures and electrically insulated from the adjacent electrodes.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects of the invention will be more clearly understood from the following description when read in connection with the accompanying drawings of which:
FIG. 1 schematically shows a conventional ion trap mass spectrometer.
FIG. 2 schematically shows an ion trap mass spectrometer with improved ion trap electrodes.
FIG. 3 is a graph of the error of the RF potential within a conventional ion trap generated using the program SIMION 3d Version 6.0
FIG. 4 is a graph of the error of the RF potential within a quadrupole ion trap with the shim electrodes having the same RF voltage applied thereto as the corresponding end cap.
FIG. 5 is a graph of the error of the RF potential within a quadrupole ion trap, with the shim electrodes having an RF voltage applied thereto which is 9% of the amplitude, but 180 degrees out of phase with the RF potential applied to the ring electrode.
FIG. 6 shows a mass spectrometer with a trap in accordance with another embodiment of the invention.
FIG. 7 shows an ion trap mass spectrometer in accordance with still another embodiment of the invention.
FIG. 8 schematically shows a linear ion trap mass spectrometer with improved ion trap electrodes.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, an ion trap mass spectrometer in accordance with the prior art is schematically illustrated. The mass spectrometer includes an ion trap 1 having a ring electrode 12 and end cap electrodes 13 and 14 . The electrode 13 includes an aperture 16 through which electrons formed by the electron gun 17 may be injected into the ion trap volume to ionize a sample. Alternatively, the sample may be ionized externally and the ions injected into the trap through the aperture 16 . In either event, ions of interest are introduced into the trap. The lower end cap 14 includes an aperture 18 , which allows ions to escape the trapping volume 19 of the ion trap. These ions are then detected by the electron multiplier 21 . The output of the electron multiplier is pre-amplified by pre-amplifier 22 and supplied to an associated processor (not shown). A fundamental RF generator 23 applies suitable voltage between the ring electrode 12 and end caps 13 and 14 to generate quadrupole trapping potentials within the ion trap volume 19 . The potentials trap ions over a predetermined mass range of interest. The RF generator is controlled via a computer controller 24 . The end caps are connected to the secondary of a transformer 26 , which applies supplemental or excitation voltages across the end caps. The primary of the transformer 26 is connected to supplemental RF generator 27 . Operation of the supplemental RF generator is controlled by the computer controller 24 .
In one mode of operation (MS), to determine the mass of ions trapped in the trapping volume by the RF trapping potentials, the supplemental voltage is employed to cause ions having a mass excited by a given frequency of supplemental RF voltage to be ejected from the ion trap through the aperture 18 where they are detected by the electron multiplier 21 . In another mode of operation (MS/MS), the supplemental voltage has a frequency which excites parent ions. The energy applied to the end caps causes a trapped parent ion to undergo collision-induced dissociation (CID) with background neutrals. A second sequential supplemental RF pulse is then applied and the daughter ions of interest are ejected for detection.
In accordance with the present invention, the ion trap end cap electrodes are modified by providing shim electrodes within the apertures 16 and 18 to compensate for electric potential faults in the quadrupolar ion trap. Referring particularly to FIG. 2, wherein the same reference numbers have been used for like parts, shim electrodes 41 and 42 are associated with the end cap electrodes 13 and 14 , respectively. The shim electrodes include a cylindrical portion 43 , 44 which extend into and are spaced from the apertures 16 and 18 of the end cap electrodes 13 and 14 . The cylindrical shim electrodes include apertures 46 and 47 . Aperture 46 permits the introduction of ions from an ion source or electrons which ionize sample within the trap volume 19 . The aperture 47 permits the ejection of ions from the ion trap into the electron multiplier. In one mode of operation, an RF voltage at the frequency of the fundamental RF trapping voltage and 180 degrees out of phase therewith is applied to the shim electrodes by the shim lens RF generator 48 . In FIG. 2, the end of the cylindrical shim electrode is flush with the inner surface of the end cap electrodes. However, the ends of shim electrodes may extend into the trapping volume, FIG. 6, or may be indented, FIG. 7 .
A computer simulation was carried out using SIMION-3D, Version 6.0 program and the errors of the electric potentials inside a quadrupole ion trap were plotted for three examples: 1) with apertured end cap electrodes only, 2) with apertured end plate electrodes with flush cylindrical shim electrodes, both maintained at the same RF voltage, and 3) with flush shim electrodes with, however, a voltage applied to the shim electrodes 180 degrees out of phase with the RF voltage applied to the ring electrode and having a magnitude less than that of the fundamental RF voltage. The electric potentials inside the ion trap, especially at the region of the holes in the end cap, are shown for a 0.060 in. hole in each end cap without a shim electrode and with a shim electrode having an internal diameter of 0.060 inches and an outer diameter of 0.080 inches placed in each 0.100 in. hole with one end flush with the surface of the end cap. A fundamental RF voltage of approximately 1,000 volts was applied. The shim voltage was between 50 and 100 volts. FIG. 3 shows substantial electric potential faults 51 near the end caps caused by the entrance and exit apertures, FIG. 4 shows little improvement of electric potential faults 52 , but FIG. 5 shows a substantial improvement of electric potential faults 53 . Thus, it is clearly apparent that the shim electrode with a proper voltage has a substantial effect on the configuration of the electric potentials within the ion trap volume 19 .
We have found that, in certain instances, greater improvement can be achieved by having the shim electrodes extend into the trapping volume beyond the surface of the end cap electrodes as shown at 56 , FIG. 6 . In other instances improvements have been found where the ends of the shim electrodes are indented into the end cap electrode hole as shown at 57 , FIG. 7 . Thus, the configuration of mechanical modifications with shim electrodes extended, flush or indented, and electrical modifications with a localized quadrupolar potential 180 degrees out of phase with that applied to the ring electrodes have provided substantial improvement of the electric potentials within the trap volume, particularly at the end cap apertures.
Quadrupole ion traps of other configurations, as described in U.S. Pat. No. 5,420,425, are also susceptible to electric potential faults caused by apertures in the electrodes. One specific configuration, the linear quadrupole ion trap, is shown schematically in cross section in FIG. 8 . In this specific configuration, the RF trapping voltage produced by RF generator 23 is applied to only two of the opposed electrodes 61 and 62 . Electrodes 63 and 64 are connected to the secondary of transformer 26 , which applies supplemental or excitation voltages. Electrode 64 includes an aperture 65 normally used for ejection of ions to detector 21 . Electrode 64 is modified by providing a shim electrode 66 connected to the shim lens RF generator 48 to compensate for electric potential faults. The shim electrode includes aperture 67 for ion ejection. It is apparent from the teaching of U.S. Pat. No. 5,240,425 that the elongated electrodes may be curved.
One can also envision mass shifts which will be compound and shim voltage dependent. By sweeping the shim voltage magnitude while observing mass shifts, compound identity information may be obtained. Thus, it has been illustrated that with a proper combination of shim placement and applied voltage magnitude, mass shifts in compound studies can be reduced to essentially zero.
The foregoing descriptions of specific embodiments of the present invention are presented for the purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed; obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents. | There is provided a quadrupole ion trap mass spectrometer of the type having a plurality of ring electrodes and defining a trapping volume. The quadrupole potential faults arising from apertures in the electrodes are corrected by an apertured shim electrode placed within and spaced from the walls of the electrode apertures. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 760,882 filed Jan. 21, 1977, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to the field of coal-fired furnaces. It relates particularly to a furnace that can use coal for ignition, warm-up, and low-load stabilization.
It is sometimes desirable to use coal rather than gas or oil in electrical generating facilities. In those situations, the utility will naturally have a coal-fired unit built rather than an oil-fired unit. However, even in coal-fired units, substantial quantities of gas or oil are often used. In a typical coal-fired unit, coal to be burned in the furnace is dried and pulverized in a coal mill and delivered directly from the coal mill to the load-carrying coal nozzles in the furnace. Operation of the coal mills requires that heated air be supplied to the mills for drying and conveying the coal. This air is supplied by a forced-draft fan that forces the air through an air preheater, a device that uses the hot products of combustion in the furnace to preheat the air. This preheated primary air, the air used for drying and conveying coal, is delivered with the coal to the coal nozzles and used to support combustion. The primary air is typically not sufficient in quantity to support combustion of all the coal, so secondary air is brought directly from the air preheater to the furnace to supply the rest of the air needed for combustion. The coal thus supplied with air is caused to burn due to ignition energy from the primary air, the secondary air, the heat in the coal itself, radiation and conduction from flame in the furnace, and radiation from furnace walls.
It is to be noted that almost all of these combustion energy sources presuppose that the furnace has already been operating, and, in the large furnaces used in power generation, it presupposes that the furnace has been operating for a fairly long time. Accordingly, in order to cause and sustain combustion of the coal, it is necessary to use an auxiliary fuel for warming up the furnace walls, for providing ignition flame, and for warming up the air preheater. This is usually the function of oil- or gas-fired ignitors and warm-up guns.
In a typical installation, a relatively high-capacity oil burner is started by an ignitor, and this starts the process or warming up the furnace walls and the heat-exchange surfaces of the air preheater. This can take some time, and the use of 70,000 gallons of oil in a 900-megawatt unit for one startup alone is not uncommon. In addition, there is considerable capital expense involved in providing the hardware that is used for supplying oil. Once the furnace has been brought up to temperature, the coal nozzles are ignited by oil- or gas-fired ignitors or by the warm-up guns themselves.
The use of auiliary fuel is not necessarily over when the coal nozzles have started to supply coal. At higher boiler loads--that is, when the amount of coal supplied by the nozzles is great--the furnace can typically maintain stable combustion of the pulverized coal. However, when the load goes down and the coal supply is thereby decreased, the stability of the pulverized coal flame is also decreased, and it is therefore common practice to use the ignitors or warm-up guns to maintain flame in the furnace, thus avoiding the accumulation of unburned coal dust in the furnace and the associated danger of explosion.
All of these functions of the oil- or gas-fired burners rely on the greater ease of ignition of these fuels; less heat is required, from whatever source, to liberate the volatiles and thereby initiate or sustain combustion. Conversely, the greater difficulty encountered in igniting coal is the reason why it has typically not been used for the ignition, warm-up and low-load-stabilization functions. An incidental advantage of oil and gas that also contributes to the greater desirability of their use for these functions is that it is possible to supply them in relatively small pipes, thereby keeping their contribution to the congestion in the fuel-nozzle area to a minimum. The usual method of supplying coal to nozzles has required rather large piping, and the addition of more large-size piping would not be welcome in the area immediately behind the fuel nozzles.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to accomplish the functions of ignition, warm-up, and low-load stabilization with the use of a minimum of auxiliary fuel.
Accordingly, in a furnace system that includes a furnace, a main coal nozzle arranged to direct coal into the furnace, an air preheater having a flue-gas inlet, an air inlet, and an air outlet and being positioned to receive flue gases from the furnace and transfer heat from the flue gases to the air entering the air inlet and leaving the air outlet, a main pulverizer, a conduit positioned to conduct coal from the pulverizer outlet to the main coal nozzle, means for forcing a first air stream from the preheater outlet, through the pulverizer, and into the nozzle, and means for forcing a second air stream from the preheater outlet into the furnace, there is provided according to the present invention an ignitor, warm-up, and low-load-stabilization system comprising: an ignitor nozzle positioned for ignition of coal leaving the main coal nozzle, and ignitor pulverizer for pulverizing coal, a separator for separating coal from air, means for conveying coal mixed with air from the ignitor pulverizer to the separator, means for conveying coal from the separator to the ignitor nozzle, means for causing a third air stream having a temperature higher than the temperature of either the first or the second air stream to flow to the ingitor nozzle, and a lighter, positionable near the outlet of the ignitor nozzle, for igniting coal issuing from the ignitor nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
These and further features and advantages of the invention become evident in the description of the embodiment shown in the drawings attached, wherein:
FIG. 1 is a diagrammatic view of fuel system for the load-carrying nozzles;
FIG. 2 is a diagrammatic view of the fuel system for the ignitor nozzle of the present invention; and
FIG. 3 is a side elevation, partly a cross section, of a typical ignitor nozzle for use with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the system for supplying air and fuel to the load-carrying nozzles of a pulverized-coal boiler. The furnace is generally shown at 10. A conduit 36 connects the outlet of the furnace to the flue-gas inlet of air preheater 38. Conduit 40 connects the flue-gas outlet to a stack, not shown, that releases the products of combustion to the atmosphere. A fan 42 draws from the atmosphere and blows air through the air inlet of air preheater 38. Conduit 34 connects the air outlet of air preheater 38 to windboxes 12 and 30 located on either side of the furnace. The typical furnace would actually have four windboxes, one at each corner, but, for the sake of simplicity, only two are shown. Another conduit 32 conducts air from conduit 34 to the air inlet of pulverizer 22. The outlet of pulverizer 22 is connected by conduit 21 to exhauster 20, whose outlet communicates with several conduits. Conduits 18 and 24 lead from the exhauster outlet to coal nozzles 19 and 25, which are arranged so as to direct coal fed to them into the interior of furnace 10. Nozzels 16 and 26 are fed by a second pulverizer-exhauster combination that is not shown in the drawing, while a third pulverizer-exhauster combination, also not shown, feeds nozzles 14 and 28. Again, for each pair of nozzles shown there is typically another pair of nozzles not shown that is fed by the same pulverizer.
Windboxes 12 and 30 communicate with the interior of the furnace through openings in the vicinity of the nozzles. Dampers, not shown in the drawing, control the allocation of air from the windbox among the openings.
In normal operation, coal and air enters furnace 10 through one or more elevations of nozzles. Combustion takes place in the interior of furnace 10, producing hot flue gases that flow out conduit 36, through air preheater 38, and through conduit 40 to a stack. Air preheater 38 has moving heat-exchange surfaces that alternately contact the hot flue gases and the air entering the preheater from fan 42. The surfaces thus absorb heat from the flue gases and release it to the air from fan 42. Part of the heated air leaving air preheater 38 passes through conduit 32 and into pulverizer 22. Pulverizer 22 is an apparatus for drying and crushing coal, and the hot air brought by conduit 32 is used to dry the coal. The air stream flowing in conduit 32 and pulverizer 22 also flows through conduit 21, exhauster 20, and conduits 18 and 24 to the associated nozzles. In flowing through pulverizer 22, the air stream entrains the coal that has been sufficiently pulverized and carries it to nozzles 19 and 25. Since fan 42 and exhauster 20 both provide motivating force for this motion, it can be seen that together they constitute means for forcing a first air stream from the air outlet of preheater 38, through pulverizer 22, and into either nozzle 19 or nozzle 25.
The air forced by fan 42 and exhauster 20 through pulverizer 22 is referred to as primary air and is delivered with the coal to main coal nozzles 19 and 25. However, there is not usually enough primary air to support combustion of all of the coal, so some of the air leaving air preheater 38 goes through conduit 34 to windboxes 12 and 30. Windboxes 12 and 30 supply the secondary air, the remainder of the air required to support combustion of all the coal.
It is evident that the above discussion presupposes that hot flue gases are flowing through conduit 36. Of course, at the beginning of furnace operation, the gases flowing through the conduit 36 are relatively cool. A typical coal-fired unit includes supplementary burners that burn oil or natural gas, and it is the function of these burners to operate when the gases coming through conduit 36 are relatively cool. This is because pulverized coal is relatively difficult to ignite, and stable combustion cannot be guaranteed unless significant amounts of heat energy are present in the combustion area. This heat energy that is used to start or maintain combustion comes from many sources. It could come directly by radiation from flame that is already in the furnace, by radiation from the walls of the furnace, by conduction from the generally hot gases in the furnace, or by conduction from the primary and secondary air flowing into the the furnace. In actuality, all of these sources contribute to the ignition energy, and at high-load conditions they all add up to a sufficient amount of ignition energy for stable combustion of the coal. However, in many situations the combustion of these energy sources is not sufficient to guarantee stable combustion. One of these situations is that of a cold furnace, in which there is little radiation from the furnace walls and little energy transferred to the primary and secondary air by the air preheater. In such cases the supplementary burners are used. Another situation in which supplementary burners are used is the case in which the furnace is operated at a relatively low load, when the amount of reactants burning is sufficiently low to cause a reduction in the energy derived from the various sources. In this case again, supplementary burners are used to maintain stable combustion. In the past, these supplementary burners have all burned oil or natural gas. This is a natural choice, since oil and natural gas are much easier to light than pulverized coal is.
FIG. 2 shows a system that enables the supplementary burners to be fired by pulverized coal. A ignitor pulverizer 110 receives air at inlet 112 from air preheater 38 of FIG. 1. Conduit 100 conducts the coal-air mixture leaving pulverizer 110 to exhauster 102, and conduit 98 connects the outlet of exhauster 102 to further conduits 96. Conduits 96 lead to cyclone separators such as separator 65. The number of such separators depends on the designer; only one is necessary, but more could be used. The outlet of separator 65 is connected by an air line 62 to a point in the interior of the furnace remote from the fuel nozzles. Bin 66 is positioned to receive the coal leaving separator 65, and the outlet of the bin is controlled by valve 67. Coal from bin 66 is fed through coal pipe 70 to approximately valved coal pipes 74, 78, and 82, each of which terminates in coal nozzles not shown in FIG. 2. Similar coal pipes 86, 90, and 94 also receive coal either from coal bin 66 or another coal bin not shown and feed it to nozzles positioned at their exits.
Those skilled in the art will recognize that it is not essential that pulverizer 110 be a separate pulverizer. The functions of pulverizer 110 and pulverizer 22 could be combined in the same pulverizer, the output being divided between a direct connection to the furnace and a connection to a separator 65. Accordingly, the main pulverizer and the ignitor pulverizer in the claims can be embodied in the same hardware.
Fan 118 draws air from the air preheater shown in FIG. 1, and this air stream is divided among conduits 119, 120 and 122. Conduit 119 feed an in-duct air heater, possibly an electric heater, and the output of air heater 116 is sent by means of conduit 114 to the ignitor nozzles at the ends of coal pipes 82 and 94. The temperature of the air leaving air heater 116 is preferably between 300° F. and 1000° F. A similar heater and similar connections exist between conduit 120 and the nozzles at the end of coal pipes 78 and 90 and between conduit 122 and the nozzles at the ends of coal pipes 74 and 86.
FIG. 3 shows an ignitor nozzle of the type that would be fed by coal pipe 82. The ignitor nozzle is actually made of three concentric nozzles 128, 130 and 134. Nozzles 128 and 134 are both fed by conduit 80, which is attached to nozzle 128 by flexible connector 126. Coal pipe 82 is connected through ball joint 138 to coal-pipe extension 144. Interior to and concentric with coal pipe 82 and coal-pipe extension 144 is lighter 142. Lighter 142 may be a small version of an ordinary coal-/or gas-fired ignitor, or it may be a high-energy arc ignitor. In either case, the ignitor is flexible at least through the area of the ball joint in order to allow it to move with coal-pipe extension 144. Air conduit 124 communicates with windbox 12 of FIG. 1 and has nozzle 130 fitted on its exit. Accordingly, nozzle 130 is in communication with windbox 12. A typical unit would have a discriminating flame detector 132 of any desired type in order to determine whether or not there is flame at the end of the ignitor nozzle.
To start up the furnace when it is cold, pulverizer 110 is started, receiving coal at its inlet and crushing it. The air inlet of pulverizer 110 receives air that has been blown through air preheater 38 by fan 42. In a cold start-up, this air is still relatively cool. The cool air is blown through pulverizer 110, conduit 100, exhauster 102, and conduits 98 and 96 to separator 65. Separator 65 removes the coal that has been entrained by the air blown through pulverizer 110, and it drops it into bin 66. Simultaneously, the air separated from the coal is exhausted into the furnace through line 62. Alternately, bin 66 could be a storage bin large enough to hold the amount of coal needed for a startup. In such a case, the pulverized coal left in bin 66 from previous operation of the furnace would fuel the operation until the furnace has heated up. Inerting line 64 is used to maintain an atmosphere in bin 66 during storage that discourages spontaneous combustion. After the furnace has heated up, ignitor pulverizer 110 starts to work, replenishing the supply of stored coal in bin 66.
Whichever method is used, coal is supplied by bin 66. Valve 67 regulates the amount of coal that is allowed to fall from bin 66, and this coal is forced by appropriate means through conduits 70 and 82 and out the ignitor nozzle. Similarly, coal is also forced through coal pipe 94 and through the nozzle fitted at its exit. Due to the fact that the coal is sent to conduits 82 and 94 with almost no air, coal pipes 82 and 94 can be made relatively small, so they do not contribute to the congestion in the furnace corners. At the same time that the coal is being delivered to the ignitor nozzles, air from preheater 38 is forced by fan 118 through conduit 119 to heater 116. Heater 116 heats the air to a temperature high enough to provide stable combustion. Without heater 116, the only heat in the air would be that imparted to it by air preheater 38, and on a cold start this is not very much heat. The hot air leaving heater 116 is fed by conduit 114 to conduits 80 and 92. Part of the air flowing through conduit 80 passes through nozzle 134 of FIG. 3. According to the present state of the art, nozzle 134 may have vanes 136 to properly direct the air flow, and this air flow imparts an appropriate flow pattern to the coal that leaves the openings of coal-pipe extension 144.
It is to be noted that the present system allows the amount of heat introduced by air heater 116 to be kept to a minimum. Since the air that is heated is used only to add to the ignition energy at the ignitor nozzle, the necessity of adding heat to the entire volume of air flowing through preheater 38 is avoided. Furthermore, since the inert water vapor that results from the drying of the coal has been separated from the coal before the coal reaches the ignitor nozzles, none of the energy supplied by air heater 116 is used up in heating inerts. The rest of the air that flows through conduit 80 is conducted through nozzle 128 and past vanes 140, which also impart a flow pattern appropriate for stable combustion. Though the amount of air heated by heater 116 will normally be kept as low as possible, system designs may provide sufficient capacity to heat 100 percent stoichiometric air if required. Thus, the amount of air supplied through nozzles 128 and 134 may be stoichiometrically sufficient for combustion of the coal. If it is not, windbox air will be introduced through nozzle 130. Even if the amount of heated air introduced through nozzles 128 and 134 is sufficient for combustion of all the coal, however, it may be desirable, depending on the characteristics of nozzles 128 and 134 and vanes 136 and 140, to introduce windbox air in order to cause a flow pattern adapted to feeding hot combustion products back into the combustion zone, thereby contributing to ignition energy and the stability of the ignitor flame.
Typically, the coal leaving coal-pipe extension 144 would have its volatiles liberated by lighter 142, and combustion of some of the coal would also be started in the presence of the air flowing through ignitor 134. The remainder of the air needed for combustion would be supplied by nozzle 128, so combustion is completed after the coal and air leaving nozzle 134 meets the air in nozzle 128. As was noted before, the air coming through conduit 80 is hot enough so that its contribution to ignition energy provides for a stable flame.
It is to be understood that the nozzle of FIG. 3 is merely illustrative; it merely shows the functions that would typically be performed by a nozzle used with the present invention.
The stable flame at the outlet of the ignitor nozzle begins to warm the furnace walls and steam pipes, and as they warm up, the flue-gas temperature increases. Eventually, the air preheater becomes hot enough for operation of the main coal nozzles, and their pulverizers are started. The coal issuing from the main coal nozzles is ignited by flame from the ignitor nozzles, and normal operation beings. If the furnace is operating at low loads, the ignitor nozzles remain on, providing low-load stabilization. It may be determined that the cost penalty in leaving the ignitors in operation is minor, so they may be left operating even at high loads.
While the invention has been described in terms of a specific embodiment, the use of a specific embodiment is by no means meant as a limitation. Accordingly, any modification within the scope of the appended claims that is apparent to those skilled in the art in light of the foregoing description is meant to be included in the invention. | An ignition, warm-up and low-load-stabilization system for furnaces fired by pulverized coal. In conjunction with a system in which pulverized coal is sent directly from a coal mill to a load-bearing nozzle and in which combustion air is brought to the nozzles from an air preheater that uses hot furnace gases to warm the combustion air, ignitor nozzles are provided that are supplied by pipes bearing coal from which the drying air has been separated. Combustion air for the ignitor nozzles is heated by an independent heat source that heats the combustion air or a portion thereof to a temperature higher than that of the air supplied by the air preheater. Such a coal-fired ignitor burner can replace oil or gas-fired ignitors and warm-up guns and thereby reduce the amount of oil or gas used in ignition, warm-up, and low-load stabilization. | 8 |
FIELD OF THE INVENTION
The present invention generally relates to agricultural equipment and machines, particularly, cotton harvesting machines (cotton pickers); and, more particularly, to cotton picker systems and apparatus for detecting overloads, overruns, or slow downs, at the picking drum.
BACKGROUND OF THE PRIOR ART
In conventional cotton pickers, for each row of cotton to be picked, there is provided a picker drum, which supports at least one vertical rotor assembly, which assembly consists of a plurality of radially extending, cotton-picking spindles. Each rotor, and its associated drive gears, are protected against damage by a slip clutch, which removes drive from the rotor when an overload occurs, e.g. when debris becomes lodged in the drum. That is, a rotor shaft extends downwardly through the slippable portion, or inner hub, at the center of the slip clutch, and then through the drum. The rotor drive gear is mounted to the external, driven portion, i.e. housing, of the slip clutch. As the slip clutch is driven by a conventional power source, via the drive gear, the rotor also rotates on its vertical axis, in tandem with the clutch.
During the overloaded condition, ratcheting or clicking sounds are generated as the cams and lobes on the drive and driven portions, of the gear train and clutch respectively, slip past each other. Absent a slippage detection system, an operator, seated in the cab of the cotton picker, must rely upon hearing the slipping sounds. However, he may not immediately hear the sounds because cabs tend to isolate the operator from the noise of the picker unit. This inability to immediately recognize the overload condition can result in damage to the drum and its drive, as well as reduced productivity from the loss of cotton.
Before now, the slippage detection systems measured the speed differential between the rotor assemblies of the picking drums. The drum rotor assembly normally comprises two rotor shafts per picking drum. Each rotor shaft of each drum, has a speed sensor, therefore there are 12 sensors on a 6 row machine. Each sensor measures the revolutions per minute (RPM) from its respective shaft and sends the signal to a computer processing unit that calculates the speed differential between the two shafts. A microprocessor captures the speed differential at each rotor assembly and the resulting average differential speed after comparing all six assemblies. The processor sends a fault warning if any rotor speed and/or speed differential deviates from the average by more than ±10%.
There are many factors influencing this fault warning. Typically, the shaft must spin a minimum number of RPMs before the computer processing unit can detect any degree of change. Most computer processors need a certain minimum number of cycles and time to process and validate signals from the speed sensor. Since damage continues to occur, during at least that minimum number of cycles, and during the processor cycle validation time, the delayed detection or late warning of the slippage leads to, inter alia, aggravation of the deterioration of various fine-tuned components of the harvester machines.
Identifying and repairing the damage to these fine-tuned components may exceed the troubleshooting capabilities of the average operator.
SUMMARY OF THE INVENTION
In a cotton-picking unit of a cotton harvester, or in other agricultural or construction equipment or in machine tools there can be an overrunning clutch having an input driven by rotable power and an output driven by the individual unit. The input and output are engaged such that the input and output are rotable relative to one another along the path of rotational movement when in an overrunning condition. The invention comprises negating the need for a complicated algorithm or use of a microprocessor unit to detect such overrunning condition, and generally comprises the following components of a non-contact detection system:
(a) a sensor operable in a first state when a predetermined magnetic field is absent, and operable in a second state when the predetermined magnetic field is present; and (b) a magnetic actuator mounted and operable for emitting the predetermined magnetic field; and (c) a shield disposed on the input or the output in a position for shielding the sensor from the actuator when the input and the output are jointly rotating in the normal condition, and such that when the input and the output are in the overrunning condition the shield will be at least intermittently positioned to expose the sensor to the magnetic field and to change the state of the sensor.
A principal aspect of the present invention employs a magnetic reed switching system having three components, i.e. an actuator magnet, a magnetic reed switch sensor, and a metallic shield therebetween. The state of the switch, i.e. “open” or “closed” changes by shielding or unshielding the magnetic flux between the sensor and the magnet.
In this invention, each rotor slippage can be detected independently, without the need for comparing average speed differentials to that of its neighboring rotor. Error due to speed averaging is avoided.
In yet another aspect of the invention, a strong slippage signal can be created without computer processing. Thus, the cost of this control system is only a fraction of the cost of prior art systems.
Also, the detection system of the present invention is easy to troubleshoot, allowing the operator to test and adjust a magnetic sensor by using a basic test-light, without the need to rotate the drums as fully nor to run the harvester engine at as high a risk. That is, the present invention allows fault detection within, for example, the first faulty ⅛ of a revolution and at near zero speed, as compared to the prior art systems where fault detection requires more movement and speed.
These aspects and others in their most preferred embodiment will become apparent from the following Detailed Description which will relate more detail regarding components of a detection system which comprise the following components:
(a) a drive gear, powered by the engine drive shaft and mounted to the external drive portion of the slip clutch;
(b) a magnetic actuator element also tied to said external drive portion of the slip clutch;
(c) an internal hub portion of said slip clutch, being keyed to the rotor shaft, and having a cover shield designed to intermittently shield magnetic flux emanating from the magnetic actuator; and
(d) at least one magnetic reed sensor switch mounted to receive magnetic flux from the actuator unless shielded by the cover shield.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of the clutch slippage detection system of this invention.
FIG. 2 is a top perspective view of the clutch slippage detection system of this invention, showing the shielded mode.
FIG. 3 is also a top perspective view of the clutch slippage detection system of this invention, but showing the unshielded mode as the drum is in the fault condition.
FIG. 4 is another top perspective view of an embodiment of the drum clutch slippage system of this invention which illustrates an auxiliary sensor.
FIG. 5 a – 5 c are illustrations of reed switch modes a) actuated (unshielded), b) unactuated by virtue of being out of range, and c) unactuated by being shielded.
FIG. 6 is an illustration of the worst case scenario with an auxiliary sensor.
FIG. 7 is a graph of the sensor signals of the present invention.
FIG. 8 a is a top view of the drum clutch of the present invention without either the reed switch or the magnetic actuator.
FIG. 8 b is a perspective view of the drum clutch.
FIG. 8 c is a perspective view of the drum clutch having its hub portion separated from the external drive portion.
FIG. 9 is a from cross-sectional view of the clutch and top portion of the rotor assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 through 9 , a rotor shaft 1 protrudes vertically through a cylindrically shaped clutch 10 . The rotor shaft 1 is affixed by key slot 11 (see FIGS. 2 and 9 ) to the internal hub 102 of clutch 10 (see FIG. 8 c ), and the hub can ratchet within the external housing 8 , which is the driven portion of clutch 10 . A cover shield 2 , shown with broken view in FIGS. 1 and 2 , is fitted over the top end of rotor shaft 1 and is keyed to rotate in engagement with rotor shaft 1 (see FIG. 9 ) at the same absolute RPMs (N 2 ) and within the same axis of rotation A ( FIG. 1 ). Cover shield 2 , along its periphery, is defined by downwardly extending fins 21 at regular intervals.
The external housing 8 , forms the outside of clutch 10 , and has mounted to its bottom, the rotor drive gear 7 , and has affixed at its edge an actuator support 6 , which carries actuator 5 . These components all rotate together, biased against clutch internal ratcheting mechanism 102 (see FIGS. 8 and 9 ). All share the same absolute input drive RPMs (N 1 ) rotating in the axis of rotation A, from the power delivered via the drive gear 7 .
When the rotor assembly 200 (see FIG. 9 ) and thus, the rotor shaft 1 , are rotating freely and without fault, the N 1 and N 2 are equal. However, when the rotor shaft 1 encounters an abnormal load or slows down due to rock, debris or branches caught in the rotor spindles, the N 1 and N 2 no longer are equal because the clutch hub 102 starts to slip within the housing 8 as springs 103 , which load pins 104 , release, leading to ratcheting sounds. That is, as the rotation of rotor shaft 1 hangs up, the clutch hub 102 begins to ratchet against the torque, of the clutch external housing 8 , provided by drive gear 7 .
The internal ratcheting hub 102 of the clutch allows a limited number of stops “n”, via pins 104 , which stops are preferably keyed to coincide with each of the fins 21 of the shield 2 , so that each stop “n” position allows one of the fins 21 , going at rate N 2 , to shield the actuator 5 when it rotates at N 1 equals N 2 . The cover shield 2 and hub 102 are keyed to the rotor shaft 1 .
A bracket 4 is fixed on the drum chassis 201 so as not to rotate. The bracket 4 supports a reed switch sensor 3 mounted to said bracket 4 so as to face the actuator 5 , for at least a certain minimum interval, during every revolution of the drive gear sprocket 7 and clutch housing 8 . Thus when N 1 and N 2 are equal, the ratchet system of the clutch hub 102 is most preferably at a stable position and therefore actuator 5 is shielded from sensor 3 , by one of the fins 21 , and, as such cannot be activated until N 1 does not equal N 2 .
Referring more particularly to FIG. 3 , a fault condition is shown, i.e. when N 1 does not equal N 2 . The rotor shaft 1 is encountering an excessive load, and the hub 102 of clutch 10 is slipping and ratcheting and the magnetic flux's pathway from actuator 5 to sensor 3 is unshielded by virtue of the fins 21 moving out of the pathway, allowing the magnetic field emitted at actuator 5 to contact the reed switch sensor 3 . The sensor 3 is thus enabled to send a fault signal. The signal is strong and can drive a load ranging from 250 milliamps to 1 amp, depending on the size of the reed switch sensor 3 . For example, the signal can drive an indicator light 300 (see FIGS. 5 a , 5 b , 5 c and 6 ) that will blink, indicating to the operator that there is a problem at the rotor in question.
FIG. 5( a ) graphically illustrates the reed switch sensor's ( 3 ) actuated mode for the unshielded position where the circuit is closed and a light 300 indicates warning that the clutch is slipping. At FIG. 5( b ) the state of the switch changes, opening the circuit and the light 300 shuts off by virtue of the actuator's ( 5 ) magnetic field being out of range of the sensor ( 3 ). FIG. 5( c ) shows an open circuit also, but it is open by virtue of the actuator 5 being shielded from its sensor ( 3 ) by shield ( 2 ).
Referring now to FIGS. 4 and 6 , an especially preferred embodiment of the present invention comprises a second sensor 9 mounted onto bracket 4 . Sensor 9 is a fail-safe element for the worst case scenario when N 2 =0, which means that there is complete blockage of rotor shaft 1 . That is rotor shaft 1 has completely stopped. One of the fins ( 21 ) on cover 2 is stuck at a position shielding sensor 3 , while the sprocket 7 is still spinning at N 1 RPMs which is not zero. The actuator 5 continuously passes near sensor 3 but is shielded from actuating it. The fault situation would be undetected but for sensor 9 which is clear to receive the magnetic signal when actuator 5 passes near by during revolution. FIG. 6 illustrates the open circuit at sensor 3 but successfully closing sensor 9 .
Referring now to FIG. 7 , a simple delay function is used to produce a signal that can be buffered to drive a variety of kinds of loads. The cost of producing this system, including the process controller mechanism is substantially less than prior art systems. | An improved clutch slippage detection system, comprising a magnetic actuator and at least one reed switch sensor located at a slip clutch, which reed switch changes its state, at the instant the clutch begins to overrun. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of application Ser. No. 13/313,431, filed Dec. 7, 2011, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] This invention relates to a ring with markings for identifying positions for setting gemstones in the future and to a method for marking the ring for the purpose of setting such gemstones in the marked positions.
[0003] Jewelers and jewelry vendors may benefit from repeated visits from customers. Those who purchase or wear jewelry, especially jewelry celebrating an event such as a wedding, may enjoy commemorating each anniversary of the event by adding a gemstone at the end of each year of marriage. Therefore, it may be desirable to provide a ring with markings or segments identifying positions for setting such gemstones in the future so as the gemstones are set into the ring on each anniversary of the event, the gemstones will be properly sized and spaced. As time passes, the purchaser or wearer may return to the jeweler on the anniversary of such event to purchase and have a gemstone set in a predetermined and marked positions of the ring. Repeat visits to set such gemstones may also provide the jeweler with additional opportunities to sell other goods and services during such visits.
[0004] Adding gemstones to a ring without such markings or segments would require the jeweler to identify a location for the new gemstone, then drill the ring to accommodate the new gemstone. The jeweler could misjudge, miscalculate or otherwise lack the precision necessary to ensure that the new gemstone(s) would be correctly sized and spaced to accommodate all the gemstones that may be desirably placed in the ring in the future. Further, because these tasks would need to be repeated each time a gemstone was added to a ring, possibly over the course of many years, there is an increased likelihood that mistakes in sizing or spacing of the gemstones would result in an unattractive ring or there will be insufficient space to include all desired gemstones. Further still, because new gemstones may be added by different jewelers, quality and aesthetic sensibilities may vary from one jeweler to the next, with each jeweler doing things differently from the last. This would risk asymmetry in size, spacing, and location of new gemstones that could negatively affect the beauty of the ring. Therefore, to ensure the gemstones are sized and placed properly, it may be desirable to create a pattern for the gemstones, then mark the ring accordingly. Markings could take into account milestones, such as the wedding itself, and five, ten, twenty-five, and fifty year anniversaries, and provide for different gemstones, for example, different types, colors, sizes, and varieties, for such milestones.
[0005] When buying a traditional ring with gemstones already set in the outer surface of a band, a buyer selects a band and a gemstone size and provides a finger measurement. The jeweler or manufacturer then determines the number of gemstones of selected size that will fit in the selected band based on gemstone size and ring dimensions including size. However, in a ring where gemstones are added over time, the number of yearly milestones, and therefore the number of gemstones that may be set in the ring are known at the outset. In that case, the jeweler or manufacturer must determine the size and spacing of the gemstones based on the number of gemstones and optionally the ring dimensions including width and outer circumference. The jeweler or manufacturer may then mark the ring for setting gemstones in the future. Such determination of gemstone sizing and spacing may be complicated by the presence of gemstones of different sizes and shapes.
[0006] In a ring where gemstones are added over time, there may be marked positions that are not yet occupied by gemstones. Therefore, it may be desirable to have a ring and method for marking a ring that provides a technique for making the desired marks on an outer surface of a ring in a reliable, repeatable manner and for automating the process for production purposes across various ring sizes and types.
SUMMARY OF THE DISCLOSURE
[0007] A ring including a shank having platforms at predetermined locations on an outer surface of the shank, where the platforms identify preferred positions for setting gemstones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a perspective view of a ring of the present disclosure. FIGS. 2 , 2 a , 2 b , 2 c , and 2 d show close up views of a portion of an outer surface of a ring of the present disclosure.
[0009] FIG. 3 shows a horizontal, cross-section view of a ring of the present disclosure.
[0010] FIG. 4 shows a vertical, cross-section view of a ring of the present disclosure.
[0011] FIG. 5 shows a flowchart according to an aspect of the method of the present disclosure.
[0012] FIG. 6 shows a flowchart according to an aspect of the method of the present disclosure.
[0013] FIGS. 7 and 8 show rings with gemstones set according to the present disclosure.
[0014] FIGS. 9-12 show gemstone spacing according to the present disclosure.
DETAILED DESCRIPTION
[0015] The ring and method of the present disclosure may be described in detail using the accompanying drawings, wherein like reference numerals represent identical or corresponding parts throughout the several views. A ring and method for marking an inside surface of a shank is described in U.S. patent application Ser. No. 12/813,196 filed on Jun. 18, 2010, the contents of which is hereby incorporated by reference in its entirety.
[0016] The Ring
[0017] FIG. 1 shows ring 10 with markings 20 as indicators for future placement of gemstones on an outer surface of ring 10 . In an aspect shown in FIG. 1 , segments 30 may be formed by recessed region 50 . Markings 20 may optionally be made on segments 30 , and gemstones 40 may optionally be set in segments 30 based on location of markings 20 . Ring 10 may be made of precious or non-precious material, including but not limited to platinum alloy, gold alloy, palladium alloy, silver alloy, or another alloy, and may be cast, die struck or machine created. Segments 30 may be formed by creating recessed region 50 around segments 30 by removing material and, in one non-limiting example, may be approximately 0.2 mm deep. Ring 10 may have a setting (not shown) to accommodate additional gemstones.
[0018] As shown in more detail in FIG. 2 , markings 20 may identify the location of gemstones and may be a symbol, such as a square, circle, or other identifier. It will be understood that marking 20 may be other characters, symbols or graphics, such as a plus sign (“+”) or asterisk (“*”). Marking 20 may be an indentation, engraving, scoring or raised portion. Markings 20 may be provided to identity to jewelers the location and optionally the size or type of gemstone that may occupy the location in the future. Markings 20 may be sized or otherwise indicate or correspond to sizes of gemstones to be set. FIG. 2 shows markings 20 that may identify a center point of placement of a gemstone. The distance between markings 20 to edge of segment 30 may be in one non-limiting example, approximately 0.2 mm.
[0019] FIGS. 3 and 4 show horizontal and vertical cross-section views, respectively. In each of those figures, gemstone 40 is shown in dashed outline.
[0020] It will be understood that the number of gemstones in ring 10 may vary in number. In two non-limiting examples discussed in more detail, markings for 26 gemstones and 51 gemstones are shown. In those examples, a first gemstone may be set to commemorate a wedding day, and the remaining 25 or 50 gemstones may be set to commemorate yearly anniversaries for the following 25 or 50 years respectively. In one example, the first gemstone may be larger than the contemplated remaining gemstones.
[0021] Determining Marking Locations and Gemstone Size
[0022] FIG. 5 shows a flowchart of a process for determining the locations of markings 20 (optional), the size and locations of segments 30 , and the size of gemstones 40 that may be accommodated by ring 10 . The dimensions of ring 10 and number of gemstones 40 to be inserted or markings 20 or segments 30 to appear on ring 10 are known and may be input by the user at Step 80 .
[0023] At Step 82 , the process determines the locations of markings 20 and/or segments 30 . Markings 20 may serve as a center point for determining the locations of segments 30 , even in cases where markings 20 are not shown on ring 10 . In one aspect, markings 20 and/or segments 30 may be centered along a centerline bisecting ring 10 and equally spaced along the outer surface of ring 10 . In that case, location of markings 20 may be identified by dividing 360 degrees by the number of markings 20 or segments 30 , which in one non-limiting example may be 26 or 51. Marking 20 may identity the center of segment 30 , and marking 20 may not be displayed on ring 10 . This calculation will yield the degrees of spacing between each marking 20 or center point of segment 30 . Segments 30 may be sized and arranged to accommodate marking 20 and/or gemstone 40 , and may be of various shapes and styles, as determined by the user. Locations for markings 20 and/or segments may be placed along a center line bisecting ring 10 .
[0024] In another aspect shown in FIG. 8 , one or more segment 30 ′ and/or one or more corresponding gemstone 40 ′ may be larger than the other segments 30 and gemstones 40 . In one non-limiting example, the larger gemstone may be referred to as a primary gemstone 40 ′ set in ring 10 and the corresponding primary segment 30 ′ may include space for a setting (not shown). In this case, when determining the location of other secondary markings 20 or secondary segments 30 , the larger size of the primary segment 30 ′ may be taken into account. In such calculation, the span of primary segment 30 ′ in degrees is subtracted from 360 degrees and that quantity divided by the number of secondary segments 30 plus one, to yield the spacing in degrees between the markings 20 or center points of segments 30 and the edge of primary segment 30 ′. In another non-limiting example where there are multiple primary gemstones 40 ′ and primary segments 30 ′ (not shown), the sizes of those larger gemstones and segments are taken into account. The quantity of primary segments 30 ′ are multiplied by the size in degrees of each primary segment 30 ′ and that number is subtracted from 360 degrees to create a first quantity. The remaining secondary segments 30 are then equally spaced between primary segments 30 ′.
[0025] In one aspect, these calculations may result in relative marking locations that may be applied to rings of various outer circumferences. In Step 84 , the gemstone size is determined. The size of primary gemstone 40 ′ is limited by width of ring 10 and/or size of primary segment 30 ′. The size of secondary gemstones 40 is limited by width of ring 10 and/or the size of the secondary segments 30 .
[0026] In one aspect, the presence of markings 20 on ring 10 may be optionally not shown on ring 10 , and location of segments 30 may serve as a guide to placement of gemstones 40 . When no markings 20 are present, a jeweler may determine the location of gemstone 40 within segment 30 . In one non-limiting example, gemstone 40 may be centered vertically with respect to the width of ring 10 and may be centered horizontally with respect to segment 30 . To determine the center point for placement of gemstone 40 , one may draw a rectangle or square around the segment 30 , then draw first line from the upper left corner to the lower right comer. One may then draw a second line from the upper right corner to the lower left corner. The intersection of the first and second lines may indicate a center of segment 30 for placement of gemstone 40 . Two, non-limiting examples of such center point determination for two segment 30 shapes are shown in FIGS. 2 a , 2 b , 2 c , and 2 d.
[0027] At Step 86 , the process outputs the location of markings 20 and/or segments 30 that may be used to mark ring 10 as described below.
[0028] Ring Marking and Gemstone Setting
[0029] FIG. 6 is a flowchart of the process of marking and setting gemstones in ring 10 . In Step 100 , the process may receive as input one or more of the following: number of markings and/or segments, marking locations, marking types, marking sizes, segment sizes, segment locations, segment styles for a specific finger size into control software. In one aspect, software such as Visual LaserStar Write (VLW) or CAD 2v1.14 and any updates may be used control a laser engraving system such as a Crawford-LaserStar Technologies 20-watt Marking Laser, 3500 Series. In other aspects, markings 20 and segments 30 may be made by a machined engraving process, including but not limited to a CNC machine or may be created during the casting process. In Step 105 , ring 10 , which may be a plain band, may be inserted into the laser engraving system and the system may engrave the markings 20 and/or form segments 30 by creating recess 50 in ring 10 . Optionally, gemstone 40 may be set into ring 10 using marking 20 to commemorate an initial event. In Step 110 , the ring is sold to a customer. Sometime later, at Step 115 , the customer may cause ring 10 to be sent to an authorized individual or business to set a gemstone in ring 10 . At Step 120 , a gem-setter or milling machine may drill a hole at one or more markings 20 or at the center point of segment 30 to accommodate a gemstone. The markings 20 or segments 30 may be used as a guide for drilling the hole size and location. A gemstone may then be set into the hole. At Step 125 , ring 10 may be returned to the owner and the process beginning at Step 115 may be repeated upon the next event or anniversary.
[0030] FIG. 7 shows a ring with gemstones 40 of one size set in locations. FIG. 8 shows a ring with one larger primary gemstone 40 ′ and other secondary gemstones 40 of smaller size set in locations.
[0031] FIGS. 9-12 show spacing of gemstone 40 according to the present disclosure. FIGS. 9 and 10 show locations and spacing for 26 gemstones 40 of one size, for ring sizes 3, 8, and 13. In FIG. 9 , gemstones 40 are shown to be set 2.061 mm, 2.656 mm, and 3.251 mm apart measured from a center point of gemstone 40 for sizes 3, 8, and 13, respectively. In FIG. 10 , gemstones 40 are shown to be set 0.890 mm, 1.483 mm, and 2.077 mm apart measured from edge to edge of gemstone 40 for sizes 3, 8, and 13, respectively.
[0032] FIGS. 11 and 12 show locations and spacing for 26 gemstones, including one primary gemstone 40 ′ and 25 secondary gemstones 40 , for ring sizes 3, 8, and 13. In FIG. 11 , all gemstones 40 and 40 ′ are set 2.061 mm, 2.656 mm, and 3.251 mm apart when measured from a center point of gemstone 40 or 40 ′ for sizes 3, 8, and 13, respectively. FIG. 12 shows an edge to edge gemstone spacing for sizes 3, 8, and 12. In FIG. 12 , for size 3, primary gemstone 40 ′ may be set 0.676 mm to adjacent secondary gemstones 40 , and secondary gemstones 40 may be set 0.890 mm apart from one another. In FIG. 12 , for size 8, primary gemstone 40 ′ may be set 1.283 mm to adjacent secondary gemstones 40 , and secondary gemstones 40 may be set 1.483 mm apart from one another. In FIG. 12 , for size 13, primary gemstone 40 ′ may be set 1.877 mm to adjacent secondary gemstones 40 , and secondary gemstones 40 may be set 2.077 mm apart from one another.
[0033] Numerous additional modifications and variations of the present disclosure are possible in view of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present disclosure may be practiced other than as specifically described herein. | A ring including a shank having platforms at predetermined locations on an outer surface of the shank, where the platforms identify preferred positions for setting gemstones. | 8 |
FIELD OF THE INVENTION
The present invention relates to an LED module, and more particularly to an LED module that provides a reliable light source and an LED light string using the LED modules.
BACKGROUND OF THE INVENTION
Presently light sources of a backlight module are mainly sorted into light emitting diodes (LEDs) and cold cathode fluorescent lamps (CCFLs). Since the light emitting diodes have advantages like low power consumption, using light emitting diodes to replace the cold cathode fluorescent lamps is the main trend of the development of backlight module industry.
Based on the concept of modular production, backlight modules, no matter direct-type or edge-type, use a light string having a plurality of light emitting diodes connected in series as the light source. Since a backlight module has to provide a stable and uniform surface light source, once one of the light emitting diodes burned out, the broken one needs to be changed immediately so as to maintain the uniformity of the surface light source. Therefore, maintenance or durability of the light strings of the backlight module is restrained by the working life of each of the light emitting diodes.
Hence, it is necessary to provide an LED module and an LED light string using the same to overcome the problems existing in the conventional technology.
SUMMARY OF THE INVENTION
The invention provides an LED module and an LED light string using the same to overcome the problem of lack of durability in a light string of a backlight module.
An LED module comprising: an input terminal, an output terminal, a primary LED, a spare LED and a switching module, wherein the switching module controls the spare LED to be switched off when the primary LED is switched on, and controls the spare LED to be switched on when the primary LED is burned out; and the switching module has a first field-effect transistor, a second field-effect transistor, a first resistor and a second resistor, wherein the source electrode of the first field-effect transistor is connected to the cathode of the primary LED and connected to ground orderly through the first resistor and the second resistor, the drain electrode thereof is connected to the output terminal, and the gate electrode thereof is connected to ground through the second resistor; the source electrode of the second field-effect transistor is connected to the cathode of the spare LED, the drain electrode thereof is connected to the output terminal, and the gate electrode thereof is connected to the gate electrode of the first switch; and the threshold voltage Vth 1 of the first field-effect transistor and the threshold voltage Vth 2 of the second field-effect transistor satisfy the following condition: Vth 1 >−(Vs 1 −Vf)R 1 /(R 1 +R 2 )>Vth 2 >−(Vs 1 −Vf), wherein Vs 1 is an input voltage received by the input terminal, Vf is the forward voltage drop of the primary LED and the spare LED, R 1 is the resistance value of the first resistor, R 2 is the resistance value of the second resistor.
An LED module comprising: an input terminal, an output terminal, a primary LED, a spare LED and a switching module, wherein the anode of the primary LED is connected to the input terminal, the cathode thereof is connected to the output terminal through the switching module; the anode of the spare LED is connected to the input terminal, the cathode of the spare LED is connected to the output terminal through the switching module; and the switching module controls the spare LED to be switched off when the primary LED is switched on, and controls the spare LED to be switched on when the primary LED is burned out.
In one embodiment of the present invention, the switching module has a first switch and a second switch, wherein the first switch is connected to the cathode of the primary LED and the output terminal, and the second switch is connected to the cathode of the spare LED and the output terminal, wherein when the primary LED is switched on, the first switch is switched on and the second switch is switched off; when the primary LED is burned out, the first switch is switched off and the second switch is switched on.
In one embodiment of the present invention, the switching module further has a first resistor and a second resistor, wherein the cathode of the primary LED is connected to ground orderly through the first resistor and the second resistor.
In one embodiment of the present invention, the switching module has a first field-effect transistor, a second field-effect transistor, a first resistor and a second resistor, wherein the source electrode of the first field-effect transistor is connected to the cathode of the primary LED and connected to ground orderly through the first resistor and the second resistor, the drain electrode thereof is connected to the output terminal, and the gate electrode thereof is connected to ground through the second resistor; the source electrode of the second field-effect transistor is connected to the cathode of the spare LED, the drain electrode thereof is connected to the output terminal, and the gate electrode thereof is connected to the gate electrode of the first switch.
In one embodiment of the present invention, the first field-effect transistor and the second field-effect transistor are p-channel metal-oxide-semiconductor field-effect transistors.
In one embodiment of the present invention, the threshold voltage Vth 1 of the first field-effect transistor and the threshold voltage Vth 2 of the second field-effect transistor satisfy the following condition: Vth 1 >−(Vs 1 −Vf)R 1 /(R 1 +R 2 )>Vth 2 >−(Vs 1 −Vf), wherein Vs 1 is an input voltage received by the input terminal, Vf is the forward voltage drop of the primary LED and the spare LED, R 1 is the resistance value of the first resistor, R 2 is the resistance value of the second resistor.
An LED light string comprising: multiple serial-connected LED module s, wherein each LED module has an input terminal, an output terminal, a primary LED, a spare LED and a switching module, wherein the anode of the primary LED is connected to the input terminal, the cathode thereof is connected to the output terminal through the switching module; the anode of the spare LED is connected to the input terminal, the cathode of the spare LED is connected to the output terminal through the switching module; and the switching module controls the spare LED to be switched off when the primary LED is switched on, and controls the spare LED to be switched on when the primary LED is burned out.
In one embodiment of the present invention, the switching module has a first switch and a second switch, wherein the first switch is connected to the cathode of the primary LED and the output terminal, and the second switch is connected to the cathode of the spare LED and the output terminal, wherein when the primary LED is switched on, the first switch is switched on and the second switch is switched off; when the primary LED is burned out, the first switch is switched off and the second switch is switched on.
In one embodiment of the present invention, the switching module further has a first resistor and a second resistor, wherein the cathode of the primary LED is connected to ground orderly through the first resistor and the second resistor.
In one embodiment of the present invention, the switching module has a first field-effect transistor, a second field-effect transistor, a first resistor and a second resistor, wherein the source electrode of the first field-effect transistor is connected to the cathode of the primary LED and connected to ground orderly through the first resistor and the second resistor, the drain electrode thereof is connected to the output terminal, and the gate electrode thereof is connected to ground through the second resistor; the source electrode of the second field-effect transistor is connected to the cathode of the spare LED, the drain electrode thereof is connected to the output terminal, and the gate electrode thereof is connected to the gate electrode of the first switch.
In one embodiment of the present invention, the first field-effect transistor and the second field-effect transistor are p-channel metal-oxide-semiconductor field-effect transistors.
In one embodiment of the present invention, the LED modules are orderly assigned as L 1 , L 2 , . . . Li, . . . ,Ln, wherein n≧2, and 1≦i≦n, the threshold voltage Vth 1 of the first field-effect transistor and the threshold voltage Vth 2 of the second field-effect transistor of each LED module Li satisfy the following condition: Vth 1 >−(Vs 1 −i*Vf)R 1 /(R 1 +R 2 )>VTh 2 >−(Vs 1 −i*Vf), wherein Vs 1 is an input voltage received by the input terminal, Vf is the forward voltage drop of the primary LED and the spare LED, R 1 is the resistance value of the first resistor, R 2 is the resistance value of the second resistor, and Vs 1 −(n*Vf)>0.
Comparing with the conventional technology, the LED module of the present invention includes a primary LED, a spare LED and a switching module, wherein the switching module controls the spare LED to be switched off while the primary LED is switched on; and controls the spare LED to be switched on while the primary LED is burned out. Therefore, an LED light string using the LED modules can continue to provide a stable light source while one primary LED is burned out, and thereby has better durability.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of a preferred embodiment of an LED module in accordance with the present invention; and
FIG. 2 is a circuit diagram of a preferred embodiment of an LED light string in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The foregoing objects, features and advantages adopted by the present invention can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings. Furthermore, the directional terms described in the present invention, such as upper, lower, front, rear, left, right, inner, outer, side and etc., are only directions referring to the accompanying drawings, so that the used directional terms are used to describe and understand the present invention, but the present invention is not limited thereto.
With reference to FIG. 1 , FIG. 1 is a circuit diagram of a preferred embodiment of an LED module in accordance with the present invention. The LED module L has an input terminal (not labeled), an output terminal (not labeled), a primary LED 1 , a spare LED 2 and a switching module S. The input terminal receives an input voltage Vs 1 . The output terminal outputs an output voltage Vs 2 .
The anode of the primary LED 1 and the anode of the spare LED 2 are both connected to the input terminal. The forward voltage drop of the primary LED 1 and the spare LED 2 is Vf.
The switching module is connected to the cathode of the primary LED 1 and the cathode of the spare LED 2 , and controls the spare LED 2 to be switched off when the primary LED 1 is switched on; and controls the spare LED 2 to be switched on and light up when the primary LED 1 is burned out. In detail, the switching module S has a first switch Q 1 and a second switch Q 2 , wherein the first switch Q 1 is connected to the cathode of the primary LED 1 and the output terminal. The first switch Q 1 is switched on as the primary LED 1 is switched on and lights up. When the primary LED 1 is burned out, the first switch Q 1 is switched off due to an open circuit condition. The second switch Q 2 is connected to the cathode of the spare LED 2 and the output terminal, and is switched on while the primary LED 1 is burned out and thereby switches on and lights up the spare LED 2 .
In this embodiment, the switching module S further has a first resistor R 1 and a second resistor R 2 . The first switch Q 1 is a first field-effect transistor, preferably a p-channel metal-oxide-semiconductor field-effect transistor (MOSFET), and has a threshold voltage Vth 1 , wherein the source electrode of the first switch Q 1 is connected to the cathode of the primary LED 1 , and also connected to ground orderly through the first resistor 103 and the second resistor 104 . The drain electrode of the first switch Q 1 is connected to the output terminal. The gate electrode of the first switch Q 1 is grounded though the second resistor 104 . The second switch Q 2 is a second field-effect transistor, preferably a p-channel metal-oxide-semiconductor field-effect transistor (MOSFET), and has a threshold voltage Vth 2 . The source electrode of the second switch Q 2 is connected to the cathode of the spare LED 2 . The drain electrode of the second switch Q 2 is connected to the output terminal. The gate electrode of the second switch Q 2 is connected to the gate electrode of the first switch Q 1 .
Set the resistance value of the first resistor 103 to be R 1 and the resistance of the second resistor 104 to be R 2 . The threshold voltage Vth 1 of the second switch Q 1 satisfies: Vth 1 >−(Vs 1 −Vf)R 1 /(R 1 +R 2 ); and the threshold voltage Vth 2 of the second switch Q 2 satisfies: −(Vs 1 −Vf)R 1 /(R 1 +R 2 )>Vth 2 >−(Vs 1 −Vf). Assume the node voltage on the source electrode of the first switch Q 1 is Va; the node voltage on the source electrode of the second switch Q 2 is Vb; and the node voltage on the gate electrodes of the first switch Q 1 and the second switch Q 2 is Vc.
The control method of the LED module L according to this embodiment is described as follows:
When the primary LED 1 is normally working, Va=Vs 1 −Vf, Vc=(Vs 1 −Vf)R 2 /(R 1 +R 2 ). A voltage difference between the gate electrode and source electrode of the first switch Q 1 is Vgs 1 =Vc−Va. Therefore, Vgs 1 =−(Vs 1 −Vf)R 1 /(R 1 +R 2 ). Since Vth 1 >−(Vs 1 −Vf)R 1 /(R 1 +R 2 ), therefore Vgs 1 <Vth 1 , which satisfies a switched-on condition for the first switch Q 1 , the first switch Q 1 is then switched on.
In the meantime, assume the spare LED 2 is also switched on, then Vb=Vs 1 −Vf, and the voltage difference between the gate electrode and source electrode of the second switch Q 2 is Vgs 2 =Vc−Vb, therefore, Vgs 2 =−(Vs 1 −Vf)R 1 /(R 1 +R 2 ). Since Vth 2 <−(Vs 1 −Vf)R 1 /(R 1 +R 2 ), therefore Vgs 2 >Vth 2 , which does not satisfy a switched-on condition for the second switch Q 2 , and thereby the assumption fails, and the spare LED 2 should be switched off in the meantime.
When the primary LED 1 is burned out, Vc=0, and Vgs 1 =0 for the first switch Q 1 , therefore the first switch Q 1 is switched off. In the meantime, assume that the spare LED 2 is switched on and normally works, then Vb=Vs 1 −Vf and the voltage difference between the gate electrode and source electrode of the second switch Q 2 is Vgs 2 =Vc−Vb=−(Vs 1 −Vf). Since Vth 2 >−(Vs 1 −Vf), we know that Vgs 2 <Vth 2 , which satisfies the switched-on condition for the second switch Q 2 , therefore the spare LED 2 indeed is switched on.
When a plurality of the LED modules L are applied to an LED light string, the control method of the LED light string is executed by the switching module S of each LED module.
With further reference to FIG. 2 , FIG. 2 is a circuit diagram of a preferred embodiment of an LED light string in accordance with the present invention. The LED light string has multiple serial-connected LED modules as shown in FIG. 1 : L 1 , . . . ,Li, . . . Ln, wherein n≧2, and 1≦i≦n.
Each LED module L 1 includes an input terminal (not labeled), an output terminal (not labeled), a primary LED 1 , a spare LED 2 and a switching module S. The input terminal receives an input voltage Vsi. The output terminal outputs a voltage Vs(i+1).
Set the forward voltage drop of the primary LED 1 and the spare LED 2 of each LED module L 1 is Vf, and the input voltage received by the first LED module L 1 is Vs 1 . The input voltage of the LED module L 1 will be Vsi=Vs 1 −(i−1)Vf, wherein the input voltage Vs 1 of the first LED module L 1 satisfies a condition of: Vs 1 −(n*Vf)>0. Assume that the resistance value of the first resistor 103 of each LED module L 1 to be R 1 , and the resistance of the second resistor 104 of each LED module L 1 to be R 2 .
Set the threshold voltage Vth 1 of the first switch Q 1 of each LED module Li to satisfy: Vth 1 >−(Vsi−Vf)R 1 /(R 1 +R 2 )=−(Vs 1 −i*Vf)R 1 /(R 1 +R 2 ). And set the threshold voltage Vth 2 of the second switch Q 2 of each LED module L 1 to satisfy: −(Vs 1 −i*Vf)=−(Vsi−Vf)<VTh 2 <−(Vs 1 −i*Vf)R 1 /(R 1 +R 2 ). The node voltage on the source electrode of the first switch Q 1 is Vai; the node voltage on the source electrode of the seconde switch Q 2 is Vbi; and the gate electrodes of the first switch Q 1 and the second switch Q 2 is Vci.
The control method of the LED light string is described as follows:
For each LED module L 1 , when the primary LED 1 is normally working, Vai=Vsi−Vf, and Vci=(Vsi−Vf)R 2 /(R 1 +R 2 ). The voltage difference between the gate electrode and the source electrode of the first switch Q 1 is Vgs 1 =Vci−Vai=−(Vsi−Vf)R 1 /(R 1 +R 2 ). Since Vth 1 >−(Vsi−Vf)R 1 /(R 1 +R 2 ), therefore Vgs 1 <Vth 1 , which satisfies a switched-on condition for the first switch Q 1 , thereby the first switch Q 1 is switched on.
In the meantime, assume that the spare LED 2 is also switched on, thereby Vbi=Vsi−Vf. The voltage difference between the gate electrode and the source electrode of the second switch Q 2 is Vgs 2 =Vci−Vbi. Therefore, Vgs 2 =−(Vsi−Vf)R 1 /(R 1 +R 2 )=−(Vs 1 −i*Vf)R 1 /(R 1 +R 2 ).
Since Vth 2 <−(Vsi−Vf)R 1 /(R 1 +R 2 ), therefore Vgs 2 >Vth 2 , which does not satisfy a switched-on condition for the second switch Q 2 , thereby the assumption fails and the spare LED 2 in the meantime is switched off.
When the primary LED 1 is burned out, Vci=0, and Vgs 1 =0 for the first switch Q 1 , therefore the first switch Q 1 is switched off. In the meantime, assume that the spare LED 2 is switched on and normally works, then Vbi=Vsi−Vf and the voltage difference between the gate electrode and source electrode of the second switch Q 2 is: Vgs 2 =Vci−Vbi=−(Vsi−Vf). From Vth 2 >−(Vsi−Vf), we know that Vgs 2 <Vth 2 , which satisfies the switched-on condition for the second switch Q 2 , therefore the spare LED 2 indeed is in a switched-on status.
Comparing with the conventional technology, the LED module L 1 of the LED light string of the present invention includes a primary LED 1 , a spare LED 2 and a switching module S. When the primary LED 1 is normally working, the switching module S controls the spare LED 2 to be switched off; when the primary LED 2 is burned out, the switching module S then controls the spare LED 2 to be switched on. Therefore, the LED light string using the LED modules can continue to provide a stable light source while one primary LED is burned out, and thereby has better durability and relatively reduces repair frequency and cost.
The present invention has been described with a preferred embodiment thereof and it is understood that many changes and modifications to the described embodiment can be carried out without departing from the scope and the spirit of the invention that is intended to be limited only by the appended claims. | The present invention provides an LED module and an LED light string using the same. The LED module has an input terminal, an output terminal, a primary LED, a spare LED and a switching module. The switching module controls the spare LED to be switched off while the primary LED is switched on; and controls the spare LED to be switched on while the primary LED is burned out. Hence, the present invention extends a service life of the LED light string using the LED modules in the backlight module. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improved humidification devices for use in continuous positive airway pressure (CPAP) systems. These devices actively humidify air without the need to substantially increase water temperature. The present invention additionally relates to a method for delivering air humidified by non-heat-based humidifiers to airflow delivered to the subject with a CPAP system. The present invention may include a device to collect condensation from the humidified air and recycle the liquid for reutilization in the humidifier.
2. Technical Background
Continuous positive airway pressure (CPAP) devices are used to relieve partial or complete upper airway obstructions in a subject during sleep. A condition known as sleep apnea results when airflow is halted for more than ten seconds during sleep. Sleep apnea leads to decreased blood oxygenation and disrupts sleep. The procedure for administering CPAP treatment has been well documented. An early description can be found in U.S. Pat. No. 4,944,310 (Sullivan). CPAP treatment acts as a pneumatic splint of the airway by applying positive pressure, usually in the range 4 to 20 cm H 2 O. The air is supplied to the airway by a motor driven blower whose outlet passes via an air delivery hose to a nose and/or mouth mask sealed to a patient's face. An exhaust port is provided in the delivery tube proximate to the mask. CPAP pressure is increased on the detection of pre-defined patterns to provide increased airway pressure to subvert, ideally, the occurrence of the obstructive episodes and the other forms of breathing disorders.
Humidification is an important aspect of the CPAP procedure. The high airflow generated from the CPAP device removes moisture from a subject's nasal cavity, leaving a feeling of dryness and congestion. This dryness is uncomfortable and prevents many users from using the CPAP. In addition to dryness, non-humidified CPAP air may cause bleeding, swelling, excess mucous, congestion, or sneezing. The irritation also creates a very fertile ground for infections. The irritation may be cumulative, building up over time. The only way to reduce the irritation is to add moisture. Humidification therefore can be an important part of CPAP treatment. Besides humidification, water soluble lotions, solutions, or sprays for the nose and prescribed medications such as Nasonex and Flonase can be used to alleviate problems associated with CPAP air.
The prior art includes many references to humidification devices requiring heat (heat-based humidifiers). An example of this is found in U.S. Pat. No. 6,877,510 (Nitta). Heat-based humidifiers, such as heat vaporization humidifiers, heat the liquid as well as the airflow, increasing the maximum amount of water vapor the air can hold. They can also be adjusted to produce more or less moisture by altering the amount of heat applied. Also, the water chamber can be much smaller than in a passive humidifier. An integrated heat-based humidifier, however, cannot be heated as high as a stand-alone heated-based humidifier, due to the close proximity of the heating element to the CPAP. Also, as described below, heat-based humidifiers may produce more condensation than non-heat-based humidifiers, due to a higher temperature difference between the CPAP air and the ambient room temperature. Because of this, these humidifiers are sometimes set at lower constant humidification levels throughout the night, which reduces condensation during the coldest part of the night but prevents optimal humidification at the start and end of the night when temperatures are higher. Other main drawbacks of heat-based humidifiers are that they consume much or more electric power because of the high amount of heat needed to operate, and they require more time to begin humidification than non-heat-based humidifiers because of the need to substantially heat the humidifying liquid. Also, microbial growth is greater in heat-based humidifiers, increasing the risk of patient exposure to, for example, bacteria, yeasts, and molds. Finally, the components of heat-based humidifiers may have to be replaced more often than in non-heat-based humidifiers, as steam canisters need to be replaced every so often and can usually only be purchased from the original manufacturer of the steam humidifier. This increases time and costs associated with maintaining heat-based humidifiers as opposed to non-heat-based humidifiers.
The prior art also describes passive or “passover” humidifiers, which do not require heat. An example of this as integrated into a CPAP device is shown in U.S. Pat. No. 6,827,340 (Austin). These humidifiers are quite simple and, for the most part, self-regulating. They rely on the fact that an air stream passing over a reservoir of liquid or past a wick saturated with that liquid will pick up whatever moisture it can as it “passes over” the liquid. The higher the relative humidity, the harder it is for the air stream to pick up moisture, which is why these humidifiers are self-regulating (as humidity increases the humidifier's water-vapor output naturally decreases due to the decreasing difference in vapor pressure). Although these humidifiers are simple and do not require a heat source, there is no way to increase or decrease the amount of air humidification should this level be too low or high. Also, when integrated into a CPAP device, the surface area of the water used to humidify the air is necessarily smaller, resulting in lower humidification levels. As a result, this humidifier is only feasible in CPAPs set at lower-end pressures, as higher-end pressures will not produce adequate humidification levels. Conversely, increasing the surface area of the water contacting the air will increase the size of the humidifier, to the point where it would be difficult to integrate it into the CPAP. In these cases, the humidifier must be a separate attachment, not part of the CPAP system itself. Also, because of the larger size, these humidifiers may suffer from fill and spill problems because of the large size of the reservoir tank.
Condensation is a problem for any humidifier in a CPAP system. Because the greater the temperature difference between the ambient room temperature and the CPAP air the more condensation is produced, heat-based humidifiers are more susceptible to condensation than other humidifiers, since the air they produce is hotter than air produced in “cold” humidifiers. This is especially a problem at night, when the ambient temperature usually decreases in relation to the temperature of the humidifier. Condensation produces an accumulation of water in the CPAP tubing. This water produces a disruptive gurgling noise and added resistance to the CPAP circuit that results in large, transient fluctuations in mask pressure. Also, as little as 10 ml of condensate can cause an inspiratory pressure drop of up to 5.6 cm H 2 O. Thus, preventing the formation of condensate in the CPAP tubing is vital to ensuring CPAP therapy remains effective and tolerable. Some CPAP devices with heat-based humidifiers use heated CPAP tubing to prevent condensation, but this can be dangerous. See U.S. Pat. No. 5,537,996 (McPhee). Others use sensors which detect the ambient temperature and adjust heat output accordingly, so that the temperature of the CPAP air is never substantially greater then the temperature of the ambient air, minimizing condensation. See U.S. Pat. No. 5,558,084 (Daniell).
It is an object of the present invention to avoid the drawbacks of heat-based humidifiers and passive humidifiers in CPAP systems. It is further an object of the present invention to produce an integrated, compact, adjustable, cost-effective humidifier for use in CPAP systems. It is even further an object of the present invention to be less susceptible to contaminant growth because it operates at lower temperatures, creating a less hospitable environment for bacteria and other microbes than in heat-based humidifiers. Finally, it is even further an object of the present invention to produce less condensation by operating at temperatures much closer to ambient room temperatures, and through the use of new condensation-removal features in the CPAP device.
SUMMARY OF THE INVENTION
The present invention encompasses the inclusion of non-heat-based, active-force humidifiers into CPAP devices. These humidifier modules use techniques such as for example ultrasonics, atomization, and nebulization to increase the relative humidity of the surrounding air. Humidity is important in CPAP devices because it is vital to patient comfort and optimum health. All of these various, non-heat-based humidifier modules are components of a CPAP device, and all may employ various procedures and devices for dealing with excess condensation. Most importantly, these humidification modules avoid the main problems associated with heat-based humidifiers, such as the added cost and time needed to operate these humidifiers, the excess condensation produced, and the increased likelihood of microbial growth.
Non-heat, active-force humidifiers do not require heat, as distinguished from heat-based (vaporization) humidifiers, and work by applying substantial mechanical force onto a body of water to produce particles small enough for humidification, as distinguished from passive humidifiers. These humidifiers accomplish this active application of mechanical force through various methods, causing the liquid to break up into fine particles, which are then absorbed into the air. In some instances these particles are as small as those in steam. Producing humidification this way produces lower rates of microbial growth and significantly lower energy consumption than, for example, steam humidification, as well as lower maintenance hassles and costs. This process also gives a greater ability to control humidification levels and allows the CPAP device to create a smaller footprint than would be possible using passive humidifiers.
The present invention describes the humidification module device as well as methods for delivering air humidified by that device to the patient. A non-heat-based, active-force humidification module is an integrated component of a CPAP device. The airflow traveling through the CPAP device picks up humidified air from the humidification module before it travels to the subject. Condensation can be eliminated before reaching the mask of the subject through a condensation coil or membrane integrated into the humidification module or through any other method, including adding a reservoir to the CPAP device separate from the humidification module.
Examples of various embodiments of the present invention are as follows. In one embodiment, the present invention includes a continuous positive airway pressure apparatus for treating sleep apneas comprising a device for delivering a pressurized gas to a subject; and a device for actively humidifying a gas and for delivering the humidified gas to the pressurized gas without substantially heating the humidified gas prior to delivery to the subject.
In another embodiment, the present invention includes a method of treating a subject for sleep apneas comprising the steps of actively humidifying a gas without substantially heating a liquid used to humidify the gas; and delivering the humidified gas to a pressurized gas stream prior to delivery of the pressurized gas to a subject.
In yet another embodiment, the present invention includes a continuous positive airway pressure apparatus for treating sleep apneas comprising a device for delivering a pressurized gas to a subject; an ultrasonic humidifier for atomizing a liquid into a gas for creating a humidified gas; and a delivery device for delivering the humidified gas to the pressurized gas prior to delivery to the subject.
Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of a preferred embodiment for complete CPAP system, including the attached humidifier and an optional attached condensation reservoir.
FIG. 2 is a diagram showing a preferred embodiment for an ultrasonic humidifier.
FIG. 3 is a schematic drawing of a generic liquid delivery system for an atomization humidifier.
FIG. 4 is a detailed view of a preferred embodiment for an atomization humidifier.
FIG. 5 is a diagram showing the exterior of a preferred embodiment for a nebulizer humidifier.
FIG. 6 is a diagram showing a cross-section of the same preferred embodiment for a nebulizer humidifier.
FIG. 7 is a diagram detailing the preferred device for removing condensation from the humidified air, which includes the condensation coil or membrane and surrounding components.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 describes a preferred embodiment for a complete CPAP system with active humidification. This system includes the attached non-heat, active humidifier further comprised of a condenser coil for collecting and disposing of condensation before the humidified air reaches the subject. Optionally, the CPAP system may include condensation reservoir separate from the humidifier instead of an attached condensation coil.
In FIG. 1 , the subject 2 is wearing a mask 4 , preferably the nose mask 4 and/or face mask 4 , sealed to his or her face. Breathable gas in the form of fresh air, or oxygen enriched air, enters the mask 4 by flexible tubing 12 which, in turn, is connected to a motor driven blower 14 to which there is provided an air inlet 16 . The motor 18 for the blower is controlled by a motor-servo unit 20 to commence, increase or decrease the air pressure supplied to the mask 4 as CPAP treatment. The mask 4 also includes an exhaust port 8 that is close to the junction of the tubing 12 with the mask 4 . Exhaust port 8 includes a pressure release valve which releases excess air pressure that exceeds a preset amount. This amount can be adjusted depending on the air pressure needs of the patient.
Interposed between the mask 4 and the exhaust 8 is preferably a linear flow-resistive element 6 . In practice, the distance between mask 4 and exhaust 8 is very short so as to minimize deadspace volume. The mask side of the linear flow-resistive element 6 is connected by a small bore tube 40 to a mask pressure transducer 36 and to an input of a differential pressure transducer 34 . Pressure at the other side of the flow-resistive element 6 is conveyed to the other input of the differential pressure transducer 34 by another small bore tube 38 .
The mask pressure transducer 36 generates an electrical signal in proportion to the mask pressure, which is amplified by amplifier 42 and passed both to a multiplexer/ADC unit 26 and to the motor-servo unit 20 . The function of the signal provided to the motor-servo unit 20 is as a form of feedback to ensure that the actual mask static pressure is controlled to be closely approximate to the set point pressure.
The differential pressure sensed across the linear flow-resistive element 6 outputs as an electrical signal from the differential pressure transducer 34 , and is amplified by another amplifier 32 . The output signal from the amplifier 32 therefore represents a measure of the mask airflow. The linear flow-resistive element 6 can be constructed using a flexible-veined iris. Alternatively, a fixed orifice can be used, in which case a linearization circuit is included in amplifier 42 , or a linearization step such as table lookup is included in the operation of controller 24 .
The output signal from the amplifier 32 is low-pass filtered by the low-pass filter 28 , typically with an upper limit of 10 Hz in order to remove non-respiratory noise. The amplifier 32 output signal is also bandpassed by the bandpass filter 30 , typically in the range of 30 to 100 Hz to yield a snoring signal. The outputs from both the low-pass filter 28 and the bandpass filter 30 are provided to the multiplexer/ADC unit 26 . The digitized respiratory airflow (FLOW), snore, and mask pressure (P mask ) signals from multiplexer/ADC 26 are passed to a controller 24 , typically constituting a microprocessor based device provided with program memory and data processing storage memory.
The controller 24 outputs a pressure request signal which is converted to a voltage by DAC 22 , and passed to the motor-servo unit 20 . This signal therefore represents the set point pressure P set(t) to be supplied by the blower 14 to the mask 4 in the administration of CPAP treatment. The controller 24 is programmed to perform a number of processing functions.
This CPAP system is only one of many embodiments of this system, and a number of different variations may be employed to improve efficiency and/or convenience.
Also in FIG. 1 a humidifier 10 is included in the CPAP system by means of the flexible tubing 12 preferably between the linear flow-resistive element 6 and the motor driven turbine 14 . The humidifier 10 should be upstream of the linear flow-resistive element 6 for accurate flow measurements. This active humidification module can take one of many forms. Examples of these forms include ultrasonic humidification, atomization, nebulization humidification, and the like. As described above, these techniques work through active, non-heat humidification, which all utilize a means of applying substantial mechanical force to a body or stream of liquid to cause that liquid to disperse into droplets fine enough to humidify the surrounding air.
The humidification devices covered by the present invention are preferably adjustable as to the level of humidification they impart. Further preferably, the relative humidity level of the gas to be humidified can be increased by 10% with respect to the humidity of the ambient air. More preferably, the relative humidity of the gas to be humidified can be increased by 20% with respect to the humidity of the ambient air. Most preferably, the relative humidity of the gas to be humidified can be increased by 30% with respect to the humidity of the ambient air. In a preferred embodiment of the present invention, sensors can be placed to measure the humidification levels of both the humidified gas and the ambient gas in order to determine the humidity difference between these two gases.
Because the humidification devices of the present invention do not require a substantial amount of heat for humidification, they usually produce less condensation. This is due to the larger temperature difference between the heated-water humidified air and the surrounding ambient air, when compared to the air humidified by the present invention. It is more likely that liquid droplets will condense out of the hotter humidified air. Thus, preferably, the temperature of the gas humidified by the present invention is no more than 10° C. warmer than the ambient air temperature. More preferably, the temperature of the gas humidified by the present invention is no more than 5° C. warmer than the ambient air temperature.
Microbial growth is also deterred by the humidification devices of the present invention, since they do not rely on the application of a substantial amount of heat for the humidification process. By keeping the internal temperature of the CPAP apparatus lower, microorganisms such as bacteria, fungi, and molds will not grow as rapidly. Preferably, the CPAP apparatus of the present invention will show 10% less microbial growth over a period of a month than the best devices requiring a substantial amount of heat, or than what is reported in the literature, at the time this application is filed. More preferably, the apparatus will show 20% less microbial growth over a period of a month than the best devices requiring a substantial amount of heat, or than what is reported in the literature, at the time this application is filed. Finally, most preferably, the apparatus will show 30% less microbial growth over a period of a month than the best devices requiring a substantial amount of heat, or than what is reported in the literature, at the time this application is filed.
An ultrasonic humidifier is the preferred humidification device for the present invention. Ultrasonic humidifiers use of high-intensity acoustic energy to alter the properties of liquids, and can turn water into a fine mist through ultrasonic vibrations. Ultrasonic sound is sound with a frequency greater than the upper limit of human hearing (generally above 20 KHz, or 20,000 cycles per second). Ultrasonic humidification, which is an adiabatic type of system, is known for using very little energy (about 7% of the electric usage of electric steam generators). It also provides high-quality moisture and allows close control of the humidification level while requiring little maintenance. Ultrasonic humidification is the preferred way to make a steam size droplet (approximately 1 micron) without having to boil water. An ultrasonic humidifier's initial costs are often much higher than other types of systems, particularly steam systems. Also, it requires very pure water, although smaller systems can use deionized water canisters, which clean the water to approximately 2.5 ppm. While heat vaporization systems may have much lower initial costs, the money spent on replacement parts can be considerable as steam canisters need to be replaced every so often and can usually only be purchased from the original manufacturer. In addition, ultrasonic humidifiers begin humidifying immediately, while heat vaporization systems first require appreciably heating the water.
FIG. 2 shows a cross-section of an ultrasonic humidifier module which is the preferred embodiment for the present invention and can be incorporated or attached to the CPAP. Referring to FIG. 2 , the ultrasonic humidifier has an upper cabinet 46 and a lower cabinet 52 which is arranged beneath upper cabinet 46 . The bottom portion of upper cabinet 46 is open and lower cabinet 52 has a water vessel 72 which is integrally formed in the central portion of lower cabinet 52 . Upper cabinet 46 and lower cabinet 52 are connected to each other through a chassis board 78 .
A power transformer 92 , a high frequency generator 90 , and a motor-blower 88 are fixed on chassis board 78 . Motor blower 88 supplies a space 74 in water vessel 72 with air from outside. The motor blower 88 can be replaced also by using the blower from the CPAP device. A low water detector 76 is suspended below the chassis board 78 so that the low water detector 76 protrudes into the water in water vessel 72 . The low water detector 76 is magnetically operated. The low water detector 76 detects whether the level of water in water vessel 72 has fallen to below a predetermined value. The low water detector 76 comprises a float guide 64 which is perpendicularly fixed to chassis board 78 and extended in the downward direction, a magnetically operated switch 66 installed in float guide 64 , and a float 70 having two bar magnets 68 inserted in float 70 therein. Float 70 is combined with float guide 64 , to move upward and downward. When float 70 drops below the predetermined level of water according as the level of water in water vessel 72 has fallen, switch 66 is opened so high frequency generator 90 is stopped. When float 70 is in a position above the predetermined level, switch 66 is closed so high frequency generator 90 is operated.
A mist conduit pipe 60 which is comprised of an ultrasonic wave isolating material such as a plastic material is fixed to chassis board 78 . The upper portion of mist conduit pipe 60 projects through upper cabinet 46 above upper cabinet 46 , and the lower portion of mist conduit pipe 60 extends to near the bottom of water vessel 72 in lower cabinet 52 . An outlet 86 is installed on the upper end of mist conduit pipe 60 . An ultrasonic vibrator assembly 58 is fixed onto the lower end of mist conduit pipe 60 . An ultrasonic vibrator (not shown) is installed in ultrasonic vibrator assembly 58 . A plurality of holes 56 are formed in the lower peripheral portion of mist conduit pipe 60 . Preferably, holes 56 are formed at the position just above the predetermined level of water in water vessel 72 . A coaxial cable 62 for supplying the ultrasonic vibrator with high frequency energy is connected between high frequency generator 90 and ultrasonic vibrator assembly 58 . A water supply tank 48 is removably placed in upper cabinet 46 . The water supply tank 48 has an outlet pipe 50 projecting into water vessel 72 , and a handle 94 for easily removing water supply tank 48 from upper cabinet 46 .
A cap 54 having a valve mechanism is installed on the lower end of outlet pipe 50 . The valve mechanism automatically supplies water vessel 72 with water to maintain the standard level determined by the lower end of cap 54 . The upper cabinet 46 is covered with a top plate 80 except at the portion for mounting and removing water supply tank 48 . A power switch 84 for keeping power transformer 92 or high frequency generator 90 operative or inoperative, and a lamp 82 kept lighted while power switch 84 is closed, keeping power transformer 92 and high frequency generator 90 operative, are provided on top plate 80 .
When the water in water vessel 72 is positioned at the standard level, if power switch 84 is closed on, power transformer 92 , high frequency generator 90 , and motor blower 88 are in an operating state so a high frequency electric power will be fed to the ultrasonic vibrator through coaxial cable 62 from high frequency generator 90 . Therefore, a high frequency energy generated from the ultrasonic vibrator is applied to the water in mist conduit pipe 60 to produce mist or water droplets smaller than 5 microns in diameter from the water in mist conduit pipe 60 .
As shown by an arrow in FIG. 2 , the air current fed into the space 74 of water vessel 72 by motor blower 88 flows into a mist conduit pipe 60 through holes 56 and is sprayed with the mist through outlet 86 into the flexible tubing 12 (see FIG. 1 ). When the water level in water vessel 72 lowers due to generating the mist, the pressure of the water vessel 72 is lowered. Thereby, the water in water supply tank 48 flows into water vessel 72 through outlet pipe 50 by the atmospheric pressure, so the water level recovers to the predetermined water level. If water supply tank 48 is removed, float 70 falls below the predetermined water level accordingly as the water level in water vessel 72 has fallen. In that case switch 66 is opened to stop the operation of high frequency generator 90 and motor blower 88 . At the same time, a user is automatically alerted to the shortage of water in water vessel 72 by the lighting of a warning lamp.
When the water supply tank 48 is installed in upper cabinet 46 after the water supply tank 48 is filled with water, the water in water supply tank 48 flows into water vessel 72 , so the water level in water vessel 72 recovers to the predetermined water level and switch 66 is closed to operate the humidifier.
Atomization can also be used to humidify the gas delivered to the subject. Atomization is a technique which produces droplets of liquid at a specific size and surface area. The most commonly utilized atomization techniques are pressure nozzle atomization, two-fluid nozzle atomization, and centrifugal atomization. In pressure nozzle atomization, a spray is created by forcing the fluid through an orifice. The energy required to overcome the pressure drop is supplied by a feed pump. This technique produces the narrowest particle size distribution possible. Droplet size can be controlled by altering the flow rate of the fluid through the atomizer. This is the most energy efficient atomization technique. Two-fluid nozzle atomization works by combining two fluids which are forced through a nozzle using a compressed gas. The atomization energy is provided by the compressed gas, usually air. The fluid contact can be internal or external to the nozzle. This technique produces a broad particle size distribution, and is the least energy efficient of the atomization techniques. This technique is useful for making extremely fine particles (10-30 micron) because of relatively high wear resistance. This technique is also useful for small flow rates typically found in pilot scale dryers. The initial cost can be lower due to the absence of a pressure pump, as found in pressure nozzle atomization, or a rotary atomizer, as found in centrifugal atomization. Centrifugal atomization creates a spray by passing the fluid across or through a rotary atomizer (a rotating wheel or disk). The energy required for atomization is supplied by the atomizer motor. A broad particle size distribution is generated. The average particle size for most products is no greater than 100 microns. Centrifugal atomizers are usually the most resistant to wear. This technique requires relatively high gas inlet velocity to prevent wall buildup. However, control of wall buildup is otherwise minimal, due to direction of spray (horizontal) and broad particle size distribution, forcing the dryer to be relatively large in diameter. The initial cost of a centrifugal atomizer is typically high. The comparatively larger diameter of the spray dryer can increase the initial cost. As with any high speed rotating machine, maintenance costs are also high. A problem with the centrifugal atomizer will shut down spray drying operations, unlike pressure nozzle atomization with multiple nozzle spray dryers, where a problem with one nozzle will not affect the operation of the other nozzles.
FIGS. 3 and 4 show an embodiment of an atomizer module or attachment of the present invention. In FIG. 3 a generic liquid delivery system is indicated generally as 111 . The delivery system 111 includes a liquid source 112 that contains the liquid to be delivered. A liquid supply line 98 supplies the liquid to the input of a pump 108 via a pre-pump filter 110 . The pump 108 directs the liquid through a post-pump filter 106 , a regulating valve 104 , a flow meter 96 , and finally to the input of the atomizer 100 . An electronic control unit 102 receives input signals from the flow meter 96 . Based on these feedback signals, the control unit 102 determines the appropriate power to deliver to the pump 108 to control the liquid flow rate. In addition, regulating valve 104 may be electronically adjustable so that the control unit 102 may control the liquid pressure “on-the-fly” should this be desired.
FIG. 4 shows a preferred embodiment of an atomization humidifier. This embodiment shows a pressure nozzle atomizer. This embodiment is basically a hollow tube 116 (shown here with a circular cross-section, although other shapes can be used), having a length L, an internal diameter D, a wall thickness T, an inlet end 120 and an outlet end 122 . The material used in tube 116 is dependent on the overall size of the atomizer, liquid type, and other factors, although stainless steel has proved satisfactory. The physical mounting of the tube 116 can be provided by internal or external threaded portions of the tube 116 , press fitting the tube or any other method that provides adequate strength while allowing liquid to freely flow therethrough.
In operation, liquid enters the inlet end 120 of the atomizer 114 from supply line 98 . Upon exiting the outlet end of the tube 116 , the pressure of the liquid drops rapidly, resulting in atomization of the liquid. The atomized liquid thereby produced is comprised of extremely small droplets (on the order of a few microns). A sleeve 118 of additional material may be installed over the entire length of tube 116 or only along a portion of the tube 116 . The sleeve 118 can simply add structural strength to the atomizer 114 , or may provide electrical and/or thermal insulation between the atomizer 114 and other apparatus components.
Nebulization can also be used to deliver humidified air in the CPAP of the present invention. A nebulizer changes liquids into fine droplets (in aerosol or mist form) that are inhaled through a mouthpiece or mask. Nebulizers can be used to deliver bronchodilator (airway-opening) medicines such as albuterol (Ventolin, Proventil or Airet) or ipratropium bromide (Atrovent). A nebulizer may be used instead of a metered dose inhaler. It is powered by a compressed air machine and plugs into an electrical outlet. Portable nebulizers, powered by an internal battery or cigarette lighter, are available for individuals requiring treatments away from home. Nebulizers come in 2 types: jet (or pneumatic) small-volume nebulizers, and ultrasonic nebulizers. Jet nebulizers pump air or oxygen, by means of an air compressor, through a liquid to turn it into a vapor, which is then inhaled through a tube-like mouthpiece similar to that of an inhaler. Ultrasonic nebulizers do not use air compressors but instead use sound vibrations to create the aerosol. The ultrasonic nebulizer humidifier is just another name for the ultrasonic humidifier, previously discussed. Both systems avoid contamination of the environment by the use of filters.
FIGS. 5 and 6 show an embodiment of a nebulizer humidifier module or attachment of the present invention. In FIGS. 5 and 6 , the nebulizer humidifier module or attachment includes a housing 142 consisting of a chamber 146 that is suited to receive and hold a fluid. The chamber is preferably substantially cylindrical; however, any of a number of shapes may be used. The chamber 146 includes an angled bottom portion 148 so that any fluid in the chamber will be directed toward one region of the bottom of the chamber to facilitate removal of all the fluid. In one embodiment, the bottom portion 148 is set at an approximate 45 degree angle in order to reduce wastage by maximizing the amount of fluid that is evacuated from the chamber for nebulization. An air outlet 126 extends away from the housing 142 and communicates with the chamber 146 . A bather 144 on the housing forces any aerosol generated in the chamber to flow up and over the barrier 144 before passing through the air outlet 126 . The indirect path formed by the barrier and the air outlet preferably helps to limit the particle size of the aerosol that escapes the chamber 146 .
Preferably, the housing is integrally formed with a lid portion 134 via a hinge 138 such that the lid portion 134 may be sealed and unsealed against the top of the housing to allow someone to fill the chamber 146 with a fluid. The lid portion 134 of the housing 142 is preferably molded as one part with the chamber 146 .
The lid 134 preferably includes a group of openings suited to receive an air inlet valve 130 , an exhalation valve 128 and a fluid channel air inlet valve 136 , respectively. A first opening 165 is sized to accommodate the exhalation valve 128 , a second opening 168 is sized to accommodate the air inlet valve 130 , and the third opening 170 is sized to accommodate the fluid channel air inlet valve 136 . The housing and lid may be constructed of a single piece of material formed by an injection molding process. Suitable materials include a plastic material, such as polypropylene, polycarbonate or a polycarbonate blend, or a metal material.
In a preferred embodiment, each of the air inlet valve 130 , exhalation valve 128 and fluid channel air inlet valve 136 is integrally formed into a valve system 132 from a single piece of flexible material. The exhalation valve 128 preferably is mounted into the first opening 165 by a center anchor 164 so that the assembled valve and opening form a butterfly configuration allowing air to escape upon exhalation and sealing upon inhalation to prevent inhalation of air through the opening. The air inlet valve 130 preferably has a duck bill valve configuration. The duck bill valve configuration is oriented with the tapered portion directed into the chamber 146 so that ambient air may be drawn in upon inhalation and so that the parallel sealing members, or lips, of the valve prevent any flow of air out of the chamber upon exhalation. An ambient air guide 166 is preferably integrally formed in, or attached to, the lid portion 134 . The ambient air guide 166 is disposed under the second opening 168 and the air inlet valve 130 so that distal opening 172 directs ambient air over the aerosol generating structure.
The fluid channel air inlet valve 136 preferably mounts into the third opening 170 and completely seals the third opening. Preferably, the fluid channel air inlet valve is a flexible membrane having a thickness that is sensitive to, and flexibly movable in response to, air pressure changes within the chamber 146 corresponding to inhalation and exhalation through the air outlet 126 . The fluid channel air inlet 171 positioned inside the chamber and directly adjacent to the fluid channel air inlet valve may be sealed and unsealed synchronously with a patient's breathing or may be manually actuated by physical contact against the outside of the valve 30 . In one embodiment, the material is flexible rubber material. Although individual valves may be fabricated separately on separate pieces of flexible material, or the valves may each be constructed from numerous individual components, the valve system 38 is preferably a one-piece, integrated construction reducing the part count and cost of manufacturing (including the cost of assembly).
A passageway 158 may be formed by a spacing between the gas nozzle 140 and nozzle cover 156 , a groove in the inner circumference of the nozzle cover, a groove in the outside of the nozzle, or a combination of grooves on the outside of the nozzle and inside of the nozzle cover. The fluid orifice 160 is positioned adjacent the pressurized gas orifice 174 . The fluid orifice is an annular orifice defined by a gap between the inner diameter of the tip of the nozzle cover and the outer diameter of the tip of the nozzle. In one preferred embodiment, the outer diameter of the tip of the nozzle is 2 mm and the inner diameter of the nozzle cover tip is 2.46 mm. Other diameters may also be used. Although a single annular orifice is shown, embodiments where the fluid outlet has other shapes, or comprises more than one discrete orifice positioned adjacent the pressurized gas orifice, are also contemplated.
In this embodiment, the fluid channel air inlet 171 is located near the top of the chamber 146 and is substantially parallel to the longitudinal axis of the chamber 146 . The distal end of the nozzle cover forms a fluid orifice such that the fluid and gas orifices 160 , 158 are substantially parallel to each other. The space between the nozzle cover 156 and the pressurized gas nozzle 140 forms the fluid passageway 158 at the distal end which leads to the fluid orifice 160 . A non-moveable diverter 162 is located adjacent the distal end. The diverter directs the gas across the fluid orifice 160 to create a venturi effect, thereby causing the fluid to be entrained into the gas stream to create an aerosol. Preferably, the diverter 162 is attached to, or integrally molded with, the nozzle cover 156 . Alternatively, the diverter may be connected to the inside of the nebulizer 124 .
The fluid channel stem 152 extends substantially vertically along the longitudinal axis of the chamber 146 . The stem has a carved out portion 150 which forms an enclosed lumen once it is assembled and mated with the recessed channel 154 in the chamber wall. The resulting fluid channel shape is substantially rectangular. In other embodiments, the recessed channel 154 and carved-out portion 150 of the fluid channel stem 152 may be constructed to cooperate and form any of a number of continuous or varying cross-sections along their lengths. In another embodiment, the recessed channel 154 and fluid channel stem 152 may combine to form a plurality of separate fluid channels. In one preferred embodiment, the chamber has a volume of approximately 50 milliliters (ml), with a maximum fluid fill volume of 5 ml. In this embodiment, the fluid channel length is approximately 22.8 mm.
The fluid channel air inlet valve 136 is a flexible membrane that on inhalation substantially seals the fluid channel air inlet 171 communicating with the fluid inlet tube. Once substantially sealed, the necessary pressure is created inside the housing in order to entrain the fluid up the fluid channel into the path of the pressurized gas causing the fluid and gas to mix resulting in an aerosol with the desired particle size characteristics. The flexible membrane is preferably very sensitive to flow and, therefore, can be triggered at low flows making the apparatus suitable for children and the elderly who typically have lower rates of inhalation. Further, the membrane can also be manually depressed. Accordingly, the patient or the caregiver can manually actuate the apparatus.
A nebulizer capable of both breath actuation and manual actuation has been disclosed where a diverter, gas orifice, and liquid orifice are maintained in a fixed position with one another at all times. Nebulization is initiated by movement of a valve over the fluid channel air inlet that is in communication with the fluid channel linking the liquid orifice with the reservoir in the chamber. By using a flexible membrane as the fluid channel air inlet valve, a very fast and reliable response to both increased and decreased pressures within the chamber of the nebulizer may be realized.
The present invention also contemplates devices such as impellers and other non-heat active-force humidifiers for use as the humidification module for the CPAP device.
Optionally, for any humidifier covered by the present invention, we can include a condensation coil (condensation membrane) droplet filter within the humidification device. This device can be used to remove larger droplets of water to ensure reduced condensation between the humidifier and subject interface. In a preferred embodiment, shown in FIG. 7 , patient circuit 201 is mounted detachably to the humidification unit 192 that is provided with a short connection tube 190 as a support member, a mounting flange 194 , and a humidifying element 186 . Connection tube 190 may be a straight tube with both end portions engaged (connected) in an airtight fashion to connection end portions 180 of patient circuit 201 . The outer diameter of connection tube 190 is set so as to be somewhat larger than the inner diameter of patient circuit 201 , in order to ensure the airtight engagement with patient circuit 192 to be connected thereto, and it may be set appropriately in accordance with the patient circuit to be employed. Further, in this case, the use of a packing, a fastening band or the like may be employed in order to enhance airtightness.
The peripheral wall on one end of connection tube 190 (e.g., on the left side in FIG. 7 ) is formed with a mounting opening 210 for mounting flange 194 . Mounting opening 210 is located at a position outside of connection end portion 180 of patient circuit 201 upon connection with connection end portion 180 and disposed so as to allow the inside of connection tube 190 to communicate with the outside thereof.
In the illustrated exemplary embodiment, mounting flange 194 consists of a flange portion 182 in a square-plate shape or the like and a cylindrical holding portion 183 . Flange portion 182 of mounting flange 194 is shaped so as to be disposed along an outer peripheral wall of connection tube 190 and it is fixed to connection tube 190 by a screw 196 so as to cover the mounting opening 210 of connection tube 190 in a tight manner. Flange portion 182 is further provided with a communicating opening 206 that allows mounting opening 210 of connection tube 190 to open to the outside in the center of flange portion 182 .
Holding portion 183 of mounting flange 194 is disposed so as to stand upright with respect to the plate surface of flange portion 182 , such that opening 206 of flange portion 182 faces an opening 212 at the base end thereof. Holding portion 183 is arranged so as to insert through mounting opening 210 of connection tube 190 over the entire length of mounting opening 210 of connection tube 190 , extending up to the center of connection tube 190 in the radial direction, and then curved on the other end side of connection tube 190 at a generally right angle (on the right end side in FIG. 7 ). An opening 184 is defined in holding portion 183 so as to face an open end of connection tube 190 . Opening 184 at one end of holding portion 183 is large enough to engage and hold humidifying element 186 , and opening 184 is arranged so as to communicate to the outside through communicating opening 206 of flange portion 6 a in holding portion 183 .
In a preferred embodiment, the humidifying element 186 consists of a cylindrical bundle of tubes through which the humidified air stream passes. Each tube in the bundle is comprised of pores large enough to allow certain size vapor particles to pass through but small enough to keep in larger size particles. These larger liquid particles collect as condensation, which are collected in reservoir 188 . Preferably, the pores are small enough to trap liquid particles in the air larger than 10 microns in diameter. However, the pore size can be adjusted to best suit the needs of the patient. Preferably, the water in the reservoir 188 may be recycled back to the corresponding humidifier holding tank (depending on which non-heat, active-force humidifier is used) or may be disposed of in any other feasible manner.
An alternative to the condensation coil or membrane could be a condensation reservoir 44 , which would be attached to flexible tubing 12 between flow-resistive element 6 and the mask 4 , all shown in FIG. 1 . This reservoir would collect any condensation forming present in the flexible tubing 12 before it could reach the humidifier and subject interface. The collected water could then be recycled back to the humidification module or disposed of by any other manner. A preferred embodiment for the reservoir may include a wall extending from the bottom of the flexible tubing 12 on the subject 2 side of the reservoir to partially obstruct the tube and to block any liquid from progressing further down the tube and thus forcing it to fall into the reservoir. In this embodiment, the reservoir would be lower than the flexible tubing 12 to allow gravity to pull the condensation into the reservoir after hitting the wall. The reservoir may be attached to the flexible tubing 12 by means of another tube or by any other means, including a spout or funnel.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | The present invention encompasses the inclusion of non-heat, active-force humidifiers into CPAP devices. These humidifier modules use for example ultrasonics, atomization, and nebulization to increase the relative humidity of the air being delivered to the patient. Humidity is important in CPAP devices because it is vital to patient comfort and optimum health. All of these various, non-heat active humidifier modules are components or attachments to a CPAP device, and all optionally employ various procedures and devices for dealing with excess condensation. Most importantly, these humidification modules avoid the main problems associated with heat-requiring humidifiers, such as the added cost and time needed to operate these humidifiers, the excess condensation produced, and the increased likelihood of microbial growth. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to the preparation of a new class of materials with Prussian blue-like structure and their use as MRI contrast agents
BACKGROUND OF THE INVENTION
[0002] Magnetic resonance imaging (MRI) is a noninvasive and nonradioactive diagnostic modality that has found increasing applications in diagnostic medicine. In general, the image contrast obtained from MRI is a function of proton density of tissues under examination and the relative longitudinal and transversal relaxation times T 1 and T 2 . Under normal conditions, the variation of proton density in different tissues is relatively small, which makes MRI contrast enhancement possible by administration of a contrast agent (CA). The latter is a chemical compound capable of altering the relaxation times of water protons in tissues. The MRI contrast agents are usually divided into two different types base on which relaxation time they can alter to a greater extend: T 1 -weighted agents and T 2 -weighted agents. A T 1 agent shortens the longitudinal relaxation time T 1 of protons from water to a greater extent than the transversal relaxation time T 2 and can brighten up the regions where the agent is present. Conversely, a T 2 agent can produce darkened spots in the tissues reached by the agent. It is estimated that ca. 30% of all clinical MRI diagnostic procedures are performed with use of a T 1 contrast agent. This amounts to over 20 million doses of MRI contrast agents administered worldwide annually. For clinical diagnostic applications, T 1 agents are superior to T 2 agents. All the T 1 agents currently used in clinical MR imaging are Gd 3+ -based paramagnetic complexes with various polyaminopolycarboxylate ligands. MRI contrast agents approved for clinical applications include
[0000]
[0003] There are two problems associated with the current generation of commercial Gd 3+ -based MRI contrast agents: (i) toxicity issue, and (ii) the low relaxivity of these agents in high magnetic fields. As set forth below, these two problems are somewhat interconnected.
[0004] Firstly, the toxicity of free Gd 3+ ions stems from the fact that the ionic radius of Gd(III) is similar to that of calcium(II). Hence, the presence of this abiological heavy metal ion in the body can disrupt the normal Ca 2+ -mediated signaling or accumulate in certain organs by forming strong complexes with biological ligands in vivo. Prior to their approval for clinical use, many in vitro studies had shown that formation of a chelate between Gd 3+ ion and a polyaminopolycarboxylate ligand molecule can provide high thermodynamic stability and kinetic inertness, thus preventing the release of toxic Gd 3+ ions.
[0005] However, the complex biochemical, pharmacokinetic and metabolic properties of such chelates render this in vitro working model unreliable for ensuring the in vivo safety. Recently, the toxicity of the Gd 3+ -based MRI contrast agents has been linked to nephrogenic systemic fibrosis (NSF) and nephrogenic fibrosing dermopathy (NFD).
[0006] Secondly, the use of high magnetic field MR instruments has been increased steadily in the recent years. The high-field scanners can greatly shorten data acquisition time, improve signal-to-noise ratio (SNR) and provide high spatial resolution. Particularly, high resolution imaging with sufficient contrast is critical for applications such as vasculature in tumors, brain perfusion in stroke and blood clot in micro vessels, etc. All the commercial T 1 agents are low molecular weight complexes. Due to the rapid molecular tumbling motion and vibrational flexibility of the small molecules, these contrast agents have relaxivity values that are only a few percent of the maximum possible value predicted by the theoretic model (i.e. Solomon-Bloembergen-Morgan theory).
[0007] Furthermore, these agents show reduced relaxivity due to the increase in Larmor frequency at higher magnetic fields. The relaxivity is the measure of efficiency of an agent. It is normally quoted as a concentration-normalized rate r 1 (mM −1 s −1 ), i.e. the amount of increase in 1/T 1 per millimole of agent. The typical commercial T 1 agent (e.g. Magnevist@) has the relaxivity of 4.1 mM −1 ×s −1 at the currently most common magnetic field strength used for clinical applications (B 0 =1.5 Tesla or T). In order to be effective at even this modest field strength, a rather high concentration (>0.1 mM) of the agent in the body is required. This means doses as high as 0.3 mmol or ˜28 mg per kilogram body weight need to be given for most clinical applications to obtain adequate image contrast. However, when the magnetic field is increased to 3.0 or 7.0 T, the performance of the commercial agents becomes very poor unless the concentration of the agent is raised accordingly. This definitely increases the risk of renal toxicity. The relaxivity of any small-molecule MRI contrast agent is dependent on molecular motion which, in turn, is dependent on molecular size and rigidity. The current strategies for increasing relaxivity in these materials are all focused on increasing molecular weight or/and on restricting molecular motion in MRI contrast agents. By attaching multiple Gd 3+ chelates through covalent or noncovalent bonding to dendrimers, polymers, high relaxivity values, ranging from 10.6 to 39.0 mM −1 ×s −1 , have been obtained at a magnetic field strength of 1.5 Tesla.
[0008] Along the same line, nanoparticles containing Gd 3+ ions with high relaxivity can be assembled using lipid-perfluorocarbon emulsions as a platform to absorb Ga 3+ -chelates with long alkyl chains. It should be noted that all these approaches use the same small molecule chelate platform, thus providing mechanisms that are only capable of increasing relaxivity, but incapable of preventing in vivo release of free Gd 3+ ions.
[0009] Inasmuch as the present invention relates to a gadolinium containing Prussian blue lattices for use in MRI, the general attributes and uses of MRI will now be set forth.
[0010] Medical imaging modalities allow the visualization of the organs within a human body. For example, computed tomography (CT) also known as computed axial tomography (CAT): employs X-rays to produce 3D images. In the U.S., there were about 62 million scans done in 2006. Although non-invasive, CT is regarded as a moderate to high radiation diagnostic technique.
[0011] Another example of medical imaging technology is positron emission tomography (PET) and single photon emission computed tomography (SPECT). PET and SPECT use a short-lived radioactive isotope that undergoes a decay to emit a positron or gamma rays. In the U.S., there are about 20 million diagnostic medical procedures done every year. Both techniques expose the patient to low-level radiation and therefore impose risk to the patient.
[0012] A further medical imaging technology is magnetic resonance imaging (MRI). MRI uses a powerful magnetic field to align the nuclear magnetization of protons in water. It provides much greater contrast than does CT. In the United States alone, millions of MRI exams are given annually.
[0013] Magnetic resonance imaging (hereinafter referred to as “MRI”) has emerged as a prominent noninvasive diagnostic tool in clinical medicine and biomedical research. Among its many advantages, MRI can produce images with large contrast to visualize the structure and function of the body. It provides detailed images of the body in any plane. MRI generally provides much greater contrast between different soft tissues of the body as compared to other techniques, making it particularly useful in musculoskeletal imaging, cardiovascular and vascular imaging, neurological imaging, oncological imaging and other body parts or functions and diseases. Unlike CT or PET, MRI uses no ionizing radiation, but instead uses a magnetic field to align the nuclear magnetization of atoms (usually hydrogen atoms) in the body. The MRI imaging techniques therefore provide high quality images without exposing the patient to any kind of harmful radiation. The diagnostic power of MRI can be further enhanced with the use of a contrast agent. It is estimated that about 30% of all clinical MRI diagnostic examinations are performed with the intravenous injection of a contrast agent. This constitutes millions of doses of MRI contrast agent administered worldwide annually.
[0014] In magnetic resonance imaging (MRI) an image of an organ or tissue is obtained by placing a subject in a strong magnetic field and observing the interactions between the magnetic spins of the protons and radiofrequency electromagnetic radiation. The magnetic spins produce an oscillating magnetic field which induces a small current in the receiver coil, wherein this signal is called the free induction decay (FID). Two parameters, termed proton relaxation times, are of primary importance in the generation of the image. They are called T 1 (also called the spin-lattice or longitudinal relaxation time) and T 2 (the spin-spin or transverse relaxation time). The time constant for the observed decay of the FID is called the T 2 * relaxation time, and is always shorter than T 2 . The T 1 , T 2 and T 2 * relaxation times depend on the chemical and physical environment of protons in various organs or tissues.
[0015] In some situations or tissues, the MRI image produced may lack definition and clarity due to a similarity of the signal from different tissues or different compartments within a tissue. In some cases, the magnitude of these differences is small, limiting the diagnostic effectiveness of MRI imaging. Image contrast is created by differences in the strength of the NMR signal recovered from different locations within the tissue or sample. This depends upon the relative density of excited nuclei (such as water protons), on differences in the relaxation times T 1 , T 2 and T 2 * of those nuclei. The type of imaging pulse sequence may also affect contrast. The ability to choose different contrast mechanisms gives MRI tremendous flexibility. In some situations, the contrast generated may not adequately show the tissues, anatomy or pathology as desired, and a contrast agent may enhance such contrast. Thus, there exists a need for improving image quality is through the use of contrast agents.
[0016] Contrast agents are substances which exert an effect on the nuclear magnetic resonance (NMR) parameters of various chemical species around them. Ordinarily, these effects are strongest on the species closest to the agent, and decrease as the distance from the agent is increased. Thus, the areas closest to the agent will possess NMR parameters which are different from those further away. Proper choice of a contrast agent will, theoretically, result in uptake by only a certain portion of the organ or a certain type of tissue (e.g., diseased tissues), thus providing an enhancement of the contrast, which in turn generates a more accurate image. Contrast agents for MRI that are available may be injected intravenously to enhance the appearance of tumors, blood vessels and/or inflammation for example. Contrast agents may also be directly injected into a joint, for MR images of joints, referred to as arthrograms. Contrast agents may also be taken orally for some imaging techniques. Contrast agents generally work by altering the relaxation parameters, T 1 , T 2 or T 2 *, such as by shortening these relaxation times.
[0017] Since MRI images can be generated from an analysis of the T 1 or T 2 parameters discussed above, it is desirable to have a contrast agent which affects either or both parameters. Much research has, therefore, centered around two general classes of magnetically active materials: paramagnetic materials (which act primarily to decrease T 1 ) and ferromagnetic materials (which act primarily to decrease T 2 ).
[0018] Paramagnetism occurs in materials that contain unpaired electrons which do not interact and are not coupled. Paramagnetic materials are characterized by a weak magnetic susceptibility, where susceptibility is the degree of response to an applied magnetic field. They become weakly magnetic in the presence of a magnetic field, and rapidly lose such activity (i.e., demagnetize) once the external field is removed. It has long been recognized that the addition of paramagnetic solutes to water causes a decrease in the T 1 parameter.
[0019] Because of such effects on T 1 a number of paramagnetic materials have been used as NMR contrast agents. However, a major problem with the use of contrast agents for imaging is that many of the paramagnetic and ferromagnetic materials exert toxic effects on biological systems making them inappropriate for in vivo use. Because of problems inherent with the use of many presently available contrast agents, there exists a need for new agents adaptable for clinical use. In order to be suitable for in vivo diagnostic use, such agents must combine low toxicity with an array of properties including superior contrasting ability, ease of administration, specific bio-distribution (permitting a variety of organs to be targeted), and a size sufficiently small to permit free circulation through a subject's vascular system or by blood perfusion (a typical route for delivery of the agent to various organs). Additionally, the agents must be stable in vivo for a sufficient time to permit the clinical study to be accomplished, yet capable of being ultimately metabolized and/or excreted by the subject.
[0020] A T 1 agent primarily acts to brighten up the tissues where the agent is present due to its ability to enhance the longitudinal relaxation rate of protons from water (1/T 1 ). All the T 1 contrast agents currently used in clinical MRI imaging are gadolinium-based paramagnetic complexes with various polyaminopolycarboxylate ligands. 4-8 Gadolinium (Gd) is a rare-earth metal that can form a stable 3+ ion with 7 unpaired electrons (4f 7 , S=7/2), the highest number of unpaired electrons (or magnetic spins) per metal center obtainable by any metallic element in the periodic table. The most noticeable feature in all these complexes is the water coordination to the metal center, which provides an important mechanism for enhancing the proton's longitudinal relaxation rate for this water and the surrounding water molecules.
[0021] Although gadolinium-enhanced tissues and fluids appear brighter on T 1 -weighted images, which provides high sensitivity for detection of vascular tissues (e.g. tumors) and permits assessment of brain perfusion (e.g. in stroke), such compounds also have problems and risks. The relaxivity decreases with increasing magnetic field, and thus higher dosages are required to achieve the same contrast with higher magnetic fields. There have been concerns raised regarding the toxicity of gadolinium-based contrast agents and their impact, particularly on people with impaired kidney function. Both the free Gd 3+ ions and the polyaminopolycarboxylate ligand molecules used to sequester the metal ions exhibit in vivo toxicity. Previously, it was assumed that the formation of a chelate between the metal ions and the ligand molecules with high thermodynamic stability and kinetic inertness can prevent the complexes from falling apart, thus reducing the toxicity. Unfortunately, the complex biochemical, pharmacokinetic and metabolic properties of such chelates often render the in vitro working model based on the thermodynamic and kinetic stability considerations inadequate for predicting their in vivo safe delivery. Use of these compounds has been linked to nephrogenic systemic fibrosis (NSF) and nephrogenic fibrosing dermopathy (NFD) for example. The renal toxicity of such agents has also prompted the US FDA to issue a public health advisory regarding the risk of using such agents. Additionally, such compounds are not possible to take orally, requiring intravenous administration, and do not act intracellularly but only extracellularly, thereby limiting their effectiveness.
[0022] The second type of contrast agents (i.e. T 2 agents) that have been recently approved for clinical use is from the family of iron oxide nanoparticles. These include superparamagnetic iron oxides (SPIO; 50-500 nm) and ultrasmall superparamagnetic iron oxides (USPIOs; 5-50 nm). In contrast to Gd 3+ -based MRI contrast agents, iron oxide nanoparticles can only increase the transverse relaxation rate of protons from water (1/T 2 ), thus producing darkened spots in the tissues where the drug is present. From the standpoint of clinical diagnostic imaging, T 2 agents produce much less useful information. Such materials have been used for liver imaging, as normal liver tissue retains the agent, but abnormal areas (e.g. scars, tumors) do not.
[0023] It should be noted that both the Gd 3+ -based T 1 agents and iron oxide-based T 2 agents are unstable in the acidic environment of the stomach, which has prevented them from being ever considered for oral delivery. Consequently, these materials can only be intravenously administered. In order to develop any new T 1 agent, the water molecules from the surroundings need to be able to exchange with the inner-sphere water molecules, and reside on the metal sites on and off, which can provide a mechanism for water's protons to significantly shorten their T 1 relaxation time, thus increasing the proton's magnetic resonance signal intensity (i.e. imaging contrast).
[0024] It would be desirable to provide MRI contrast agents which alleviates concerns with known agents and allows high contrast images to be achieved, with low toxicity. It would also be desirable to provide a MRI contrast agent that provides specific bio-distribution, cellular imaging and permits free circulation through a patient's vascular system. Further, the qualities of ease of administration, such as by oral delivery methods, and providing stability in vivo for a sufficient time to permit the clinical study to be accomplished, while being ultimately metabolized and/or excreted by the subject, are needed. It would also be advantageous to provide a contrast agent that may allow both T 1 and T 2 imaging techniques to be performed.
SUMMARY OF THE INVENTION
[0025] The contrast agents of the present invention comprise gadolinium doped (containing) Prussian blue (PB) crystals or lattices that can greatly decrease the relaxation times T 1 and T 2 of water in tissues as well as have very low leach rates because of a low solubility product constant of the parent Prussian blue structure in strong acidic solutions or water. The amount of gadolinium, i.e. Gd 3+ ion that is substituted for the original ferric ion, i.e. Fe 3+ ion, in the Prussian blue lattice can range from about 1% to about 100%, desirably from about 10% to about 90%, and preferably from about 10% to about 50% of the total Fe 3+ ions originally present. The contrast agents are well suited for use in magnetic resonance imaging (MRI) and can be added to animals or human beings either intravenously or orally. Prussian blue particles are very small and desirably are of a nanosize and can have the formula A 4x Fe 4−x III [Fe II (CN) 6 ] 3+x .nH 2 O wherein A comprises Li + , Na + , K + , Rb + , Cs + , NH 4+ and Tl + , or any combination thereof, x is any number from 0 to about 1, and n is generally from about 1 to about 24. The particles are effective for specific bio-distribution (permitting a variety of organs to be targeted for contrast enhancement such as cellular imaging), and have a size sufficiently small to permit free circulation through a subject's vascular system (a typical route for delivery of the agent to various organs). Additionally, the agents are stable in vivo for a sufficient time to permit the clinical study to be accomplished, yet capable of being ultimately metabolized and/or excreted by the subject. The Gd 3+ -incorporated Prussian blue compounds, either in a bulk form or as nanoparticles, having a size of from about 5 to about 300 nm, can be used as a T 1 -weighted and/or T 2 -weighted MRI contrast agent.
[0026] Although not necessary for MRI analysis, the Gd 3+ containing Prussian blue compounds of the present invention can be taken up by cells through endocytosis. Endocytosis is the process by which cells absorb material (molecules such as proteins) from outside the cell by engulfing it with their cell membrane. It is used by all cells of the body because most substances important to the cells are large polar molecules that cannot pass through the hydrophobic plasma membrane or cell membrane. As used throughout this disclosure, a “patient” or “subject” to be treated by the subject method can mean either a human or non-human subject such as an animal, an organ, a tissue, a cell, and the like.
[0027] In general, a contrast agent comprises a Prussian blue lattice compound doped with gadolinium (Gd 3+ ) atoms.
[0028] In general, a process for forming a contrast agent, comprises the steps of: reacting gadolinium (Gd 3+ ) ions and a ferrous salt with a soluble ferriccyanide ([Fe III (CN) 6 ] 3− ), or reacting gadolinium (Gd 3+ ) ions and a ferric salt with a soluble ferrocyanide ([Fe II (CN) 6 ] 4− ); in the presence of a carboxylic acid, and forming a gadolinium (Gd 3+ ) doped Prussian blue nanoparticle lattice compound.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a perspective view showing the crystalline lattice structure of one embodiment of an idealized Prussian blue crystal;
DETAILED DESCRIPTION OF THE INVENTION
[0030] The contrast agent of the present invention is derived from Prussian blue. As background, Prussian blue has been used as a pigment in industry and for artists since about 1704. On Oct. 2, 2003, the US Food and Drug Administration (FDA) determined that Prussian blue capsules, manufactured and marketed by HEYL Chemisch-pharmazeutische Fabrik GmbH & Co. KG as Radiogardase™, were safe and approved their use for the treatment of internal contamination with radioactive cesium, radioactive thallium, or non-radioactive thallium in humans.
[0031] Prussian blue is a compound that belongs to the class of iron hexacyanoferrate (II) and has the following formula:
[0000] Fe 4 III [Fe II (CN) 6 ] 3 .nH 2 O Formula 1
[0000] wherein the value n represents an integer from 1 to about 24.
[0032] The Prussian blue compounds can also be salts having the formula:
[0000] A 4x Fe 4−x III [Fe II (CN) 6 ] 3+x .nH 2 O Formula 2
[0033] where A is an alkali metal such as lithium (Li+), sodium (Na + ), Potassium (K + ), Rubidium (Rb + ), Cesium (Cs + ), or it can be Ammonium (NH 4+ ) or Thallium (Tl + ). The value x can be any number, e.g. a fraction, from 0≦x≦1, e.g. 0.1 and n is about 1 to about 24, and preferably is from about 14 to about 16. The Prussian blue compound can be a soluble compound or an insoluble compound, wherein the insoluble compound is characterized by coordinating water molecules therein.
[0034] As apparent from the above formulas, Prussian blue is a mixed-valence iron hexacyanoferrate, i.e. Fe 2+ and Fe 3+ that is commercially available and can be made by several different processes. One process involves precipitating ferrous ferrocyanide from a solution of ferrocyanide and ferrous sulfate. Subsequent oxidation produces a complex ferri/ferrocyanide, the shade and pigment properties of which are dependent upon the oxidizing agent, reactant concentrations, pH, temperature, size of batch, and other reaction conditions. Typical oxidants include nitric acid, sulfuric acid, and potassium dichromate with sulfuric acid, perchlorates, and peroxides. Another process or synthesis of the Prussian blue nanoparticles utilizes different variations of the multicomponent reverse micelle technique, (i.e. the formation of water-in-oil microemulsions), or the direct precipitation process in a polymeric or a biological matrix. Another and preferred route utilizes an aqueous solution route for preparing Prussian blue nanoparticles that does not require the use of any organic or polymeric additives as are required for a water-in-oil micro-emulsion route. The aqueous solution route provides a simple and cost-effective approach to forming the modified or doped Prussian blue compounds of the present invention.
[0035] General Procedure for Preparation of Gd-Incorporated Prussian Blue Contrast Agents
[0000] Fe 3+ +Gd 3+ +[Fe II (CN) 6 ] 4− +Carboxylic acid→PB nanoparticles, or Formula 3
[0000] Fe 2+ +Gd 3+ +[Fe III (CN) 6 ] 3− +Carboxylic acid→PB nanoparticles Formula 4
[0036] An aqueous solution is defined as a solution in which the solvent is substantially water. The word aqueous is defined as pertaining to, related to, similar to, or dissolved in water. A proper concentration [i.e. 10 −3 to 10 3 M] of a ferric salt containing a proper amount of Gd 3+ ions, that is, a sufficient amount so that the Gd 3+ Prussian blue lattices contain from about 1% to about 100% of Gd 3+ ions therein in lieu of Fe 3+ ions, is mixed with a proper concentration [10 −3 to 10 3 M] of soluble ferrocyanide [Fe II (CN) 6 ] 4− to form a precursor solution or alternatively, a ferrous salt [10 −3 to 10 3 M] containing a proper amount of Gd 3+ ions is mixed with a proper concentration [10 −3 to 10 3 M] of soluble ferriccyanide [Fe III (CN) 6 ] 3− to form a precursor solution. The ferric salt or the ferrous salt can be a chloride, perchlorate, nitrate or a sulfate of iron (II), or of iron (III), or any other soluble salt of iron (II) or iron (III), and the Gd 3+ ion can be a salt of a chloride, perchloride, nitrate, or a sulfate or any other soluble salt of Gd 3+ . The method also utilizes the complexation of the ferric ions and Gd 3+ ions by a carboxylic acid as the precursor to reduce the rate of nucleation when this precursor reacts with ferrocyanide. The carboxylic acid is preferably added with either the gadolinium ions and iron salt, or with the soluble cyanide solution, or both, or it can be added to the reaction mixture after commencement of the reaction but before completion thereof. As the Gd 3+ -incorporated Prussian blue nanoparticles begin to form in situ, the same carboxylic acid can act as a surface-capping agent to control the size and prevent agglomeration.
[0037] A surface capping agent can be added to either one of the above-mentioned precursor solutions or both before mixing the solutions. The surface capping agent can be used to control the growth of the Prussian blue materials in the nanometer region. The surface capping agent can be a biocompatible carboxylic compound. The carboxylic compounds typically have a total of from 2 to about 12 carbon atoms and generally contain one or more carboxylic acid groups, that is, mono acids, or polyacids such as diacids, triacids, etc., that optionally, and independently, can contain 1, 2, or 3 or more hydroxyl groups and include, but are not limited to acetic acid, oxalic acid, citric acid, tartaric acid, adipic acid, or gluconic acid, or any combination thereof. The use of a carboxylic acid capping agent allows effective control of the size of the nanoparticles and stabilizes the Prussian blue nanoparticles. It was found that without the capping agent, such particles can aggregate to form precipitate containing particles larger than 300 nm in about two hours. The amount of the carboxylic acid is from about 0.1 to about 100 molar equivalents of ferric or ferrous ions used in the synthesis.
[0038] According to the present invention, the insertion of Gd 3+ ions into the Prussian blue crystalline lattice gives unexpected and synergistic properties such as with respect to high relaxivity values and low toxicity. The doping process with respect to the insertion of the Gd 3+ ions into the Prussian blue lattice whereby Fe 3+ ions are replaced is carried out in situ, that is simultaneously during the synthesis of the Prussian blue particles. While the substitution of the Gd 3+ ions for the Fe 3+ ions can be carried out post-synthetically, the same is not preferred nor desired. Post-synthetical insertion of Gd 3+ ions into the PB structure typically cannot be done because once the lattice is formed, it is too stable for replacement of metal ions. A typical in situ synthesis can be carried out with various amounts of the ferric ions replaced by the Gd 3+ ions in the starting solution, that is from 1% to about 100%, while the total concentration of the two ions is kept constant (e.g. 1 mM). After a proper amount of a carboxylic acid, is added to the above solution containing the two different ions, this precursor solution is then mixed with approximately an equimolar solution (±50%) and preferably (±10%) of either [Fe II (CN) 4− ] or [Fe III (CN) 6 ] 3− at room temperature to form the Gd 3+ -incorporated nanoparticles generally within 5 minutes. The product can be isolated by centrifugation and washing with a water-acetone mixture (30:70 v/v), preferably three times, to remove any unreacted starting materials or by-products. The substation level of Gd 3+ for Fe 3+ can range from about 1% to about 100%, desirably from about 10% to about 90%, and preferably from about 10% to about 50%. Generally, substituted amounts in excess of 50% of Gd 3+ ions in the original Prussian blue lattice, based upon the original amount of Fe 3+ , are generally unstable. The reaction temperature can vary from about 0° C. to about 100° C., desirably from about 10° C. to about 80° C., and preferably from about 10° C. to about 60° C. The proper total concentration of Gd 3+ and Fe 3+ ions in the precursor solution can range from about 10 −4 M to about 10 2 M, desirably from about 10 −3 M to about 10 M, and preferably from about 10 −3 M to 0.1 M.
[0039] The utilization of a Prussian blue lattice leads to increased molecular mass, a reduced molecular tumbling rate, as well as increased rigidity, thus resulting in much higher relaxivity values of the Prussian blue lattice containing Gd 3+ ions therein. Moreover, the strong ligand-feel effect of the CN − group and the extended three-dimensional structure results in the Gd 3+ ion containing Prussian blue having an extreme low solubility product constant, i.e. K sp =10 −41 . This extreme low solubility constant of course results in extremely low amounts of generally less than about 10 parts per million and desirably less than about 200 parts per billion of free Gd 3+ ions that are released to the aqueous solution based upon the total Gd 3+ parts (wt) in the nanoparticles such as at a pH of about 2 to about 7.5. The level of release Gd 3+ ions is so low that it falls below the test limit of the well known ICP-MS test of less than 15 parts per billion based upon the total Gd 3+ ion parts in the nanoparticles. Thus, the contrast agents of the present invention are not toxic and well within currently tolerable limits of free Gd 3+ ions by animals and humans (i.e. ppm or parts per million of Gd 3+ ions).
[0040] Another advantage of the Gd 3+ containing Prussian blue lattices are that the formed particles thereof are small, generally from about 5 to about 300 nanometers, desirably from about 10 to about 150 nanometers, and preferably from about 10 to about 50 nanometers in average diameter. The average molecular weight contained within the Gd 3+ -incorporated Prussian blue nanoparticles with the size of 50 nm can exceed one million Daltons, much higher than those of commercial Gd 3+ -chelates (i.e. several hundred Daltons). In addition, the Gd 3+ -incorporated Prussian blue nanoparticles have high structural rigidity, which results in higher r 1 relaxivity values. Another advantage of the Gd 3+ ion containing Prussian blue lattice nanoparticles is that they substantially do not agglomerate because the nanoparticle surfaces are capped by the carboxylate molecule. As known to those skilled in the art, relaxivity, i.e. r 1 , is the measure of efficiency of a contrast agent and normally is quoted as a concentration-normalized rate r 1 , i.e. mM −1 ×s −1 wherein mM −1 is the reciprocal unit concentration in millimoles of the contrast agent and s −1 is the reciprocal time in seconds. Naturally, short times can be achieved when the Gd 3+ doped Prussian blue nanoparticles are utilized as the contrast agent in an MRI apparatus.
[0041] Currently, typical commercial contrast agents have a relaxivity value (r 1 ) of approximately 4.1 mM −1 ×s −1 at the currently most common magnetic field strength of 1.5 Tesla (T). However, as noted in the Background of the Invention, in order to obtain good results with respect to the contrast agents, values higher than 0.1 millimole of contrast agent in the body is required, and this value can increase to such as high as 0.3 millimole or approximately 28 milligrams per kilogram of body weight in order to obtain an adequate contrast image. Furthermore, when the magnetic field strength is increased to 3.0 or 7.0 Tesla, performance of current commercial agents generally is poor. In contrast thereto, the Gd 3+ doped Prussian blue nanoparticles of the present invention have relaxivity values (r 1 ) that range from about 6.5 mM −1 ×s −1 to about 175 mM −1 ×s −1 , desirably from about 6.5 mM −1 ×s −1 to about 125 mM −1 ×s −1 , and preferably from about 12 mM −1 ×s −1 to about 25 mM −1 ×s −1 at the magnetic field strength of approximately 1.5 Tesla. At the magnetic field strength of 7.0 Tesla, relaxivity values for r 1 -weighted MRI ranged generally are from about 4.5 mM −1 ×s −1 to about 65, desirably from about 4.5 to about 45, and preferably from about 5.0 to about 25 mM −1 ×s −1 . Such unexpected results gave good image contrast as well. Thus, where sensitivity is necessary or indispensable, the present invention can be utilized as an MRI contrast agent. Alternatively, for routine medical screenings where high relaxivity values are not absolutely necessary, the concentration of the amount of the Gd 3+ Prussian blue nanoparticles can be reduced by as much as 10 to 100 times compared to typical contrast agents such as Magnevist™ or Omiscan™.
[0042] The following examples serve to illustrate, but not to limit the scope of the present invention with an example of the gadolinium Gd3+ Prussian blue lattice compound set forth in FIG. 1 .
EXAMPLE ONE
[0043] As an example, citrate-coated Gd 3+ -incorporated Prussian blue nanoparticles were prepared by slowly adding 20 mL of 1.0 mM solution with the mole fraction ratio of [FeCl 3 ]/[GdCl 3 ]=9:1 containing 0.5 mmol of citric acid into an equimolar K 4 [Fe(CN) 6 ] solution containing 0.5 mmol of citric acid under rigorous stirring at room temperature for three minutes. The product was isolated by centrifugation and washing with a water-acetone mixture (30:70 v/v) three times. The X-ray powder diffraction studies showed that the XRD pattern can be indexed into the cubic face-centered Prussian blue phase (space group Fm3m). Transmission electronic microscopy (TEM) analysis revealed that the nanoparticles are well-formed square platelets and narrowly distributed with an average diameter of ca. 13±3 nm. Dynamic light scattering (DLS) measurements showed the hydrodynamic diameter of the PB nanoparticles to be 20 nm. Elemental analysis confirmed the ratio of all Fe/Gd to be close to 19:1.
EXAMPLE TWO
[0044] Similar Gd 3+ -incorporated Prussian blue nanoparticles were also prepared by mixing 20 mL of 1.0 mM solution with the mole fraction ratio of [FeCl 2 ]/[GdCl 3 ]=5:5 containing 0.5 mmol of citric acid into an equimolar K 3 [Fe(CN) 6 ] solution containing 0.5 mmol of citric acid under rigorous stirring at room temperature for three minutes. The product, after isolated by centrifugation and washing with a water-acetone mixture (30:70 v/v) three times, showed virtually identical characteristics as that prepared by the above method, except that the ratio of all Fe/Gd to be close to 3:1.
EXAMPLE THREE
[0045] Yet another method for the preparation of Gd 3+ -incorporated Prussian blue nanoparticles required the use of 20 mL of 1.0 mM solution with the mole fraction ratio of [FeCl 3 ]/[GdCl 3 ]=6:4 containing 0.5 mmol of citric acid , and another solution of an equimolar K 3 [Fe(CN) 6 ] solution containing 0.5 mmol of citric acid. The two solutions were mixed in the dark, and exposed to sunlight for 30 minutes. The Gd 3+ -incorporated nanoparticles were formed slowly along with a gradual change of solution color from light green to deep blue in 5-10 minutes. The product was isolated by centrifugation and washing with a water-acetone mixture (30:70 v/v) three times, and showed the ratio of all Fe/Gd to be close to 4:1.
[0046] The Gd 3+ -PB contrast agents of the present invention are very versatile and can be utilized in numerous applications such as molecular or cellular probes for spectroscopy and microscopy, and contrast agents for various imaging modalities apparatuses.
[0047] The materials and methods as described above are not to be construed as limiting the invention to any certain application or example. The contrast agent and imaging method, or the related materials or methods disclosed herein may also be used for other medical imaging techniques, drug delivery applications, or other clinical diagnostic applications and biomedical research applications.
[0048] While in accordance with the patent statutes the best mode and preferred embodiment have been set forth, the scope of the invention is not intended to be limited thereto, but only by the scope of the attached claims. | Gadolinium +3 (Gd 3+ ) containing (or incorporated) Prussian blue lattice contrast agents that can be used as an MRI contrast agent have unexpectedly improved r 1 relaxivities of 1 or 2 magnitudes higher than the commercial Gd 3+ -chelates as well as exceedingly, non-toxic, low release of the Gd 3+ ions into an aqueous environment at a pH of about 2 to about 7.5. The Prussian blue lattice containing Gd 3+ ions therein can be used for clinical diagnosis intravenously to human beings for medical imaging. The particle sizes of the doped Prussian blue lattices are of a nanosize scale and are very stable against agglomeration. | 2 |
STATEMENT OF RELATED CASES
[0001] This case claims priority of the following U.S. Provisional Patent Applications Ser. No. 61/173,267 filed Apr. 28, 2009 and 61/174,249 filed Apr. 30, 2009. Both of these applications are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to means for disabling small water craft, such as are often used for hijacking or terrorist operations.
BACKGROUND OF THE INVENTION
[0003] Small watercraft can pose a hazard to commercial shipping and even naval ships. Regarding the former, Somali pirates have disrupted commercial shipping in the Gulf of Aden and even into the Indian Ocean. In 2008, these pirates collected in excess of $150 M in ransom from hijacked ship owners. The pirates use small craft to assault the ship; grappling hooks are used to secure lines, board the ship and seize control. Since modern merchant ships are highly automated, there are typically only small crews for onboard for defense. This enables pirates to easily overpower the crew and operate the ship after hijacking.
[0004] When maneuvering in restricted conditions, moored, or at anchor, naval vessels are particularly vulnerable to attack from a group of small, fast boats. Due to their size, speed, and maneuverability, these small boats can attack and then run and hide from larger navy vessels. To make matters worse, hostiles will often be operating in their own waters where they will typically enjoy a significant numerical advantage and superior knowledge of the waterways. This type of attack, which is referred to as a “small-boat-swarm,” is the tactic of choice for terrorists.
[0005] There are no truly cost-effective options for addressing the piracy issue. The naval response to small-boat-swarm has been to deploy similarly-sized, stealthy, fast, heavily-armed craft. An appropriately outfitted Zodiac-type raft has been used for this service. But even highly-trained navy personnel have a limited capability to withstand the repeated shock to their bodies that occurs when traveling in such craft at high speed in moderately high sea states.
SUMMARY OF THE INVENTION
[0006] The present invention provides a cost effective and non-lethal way to disable a small boat, such as used by pirates or terrorists. In accordance with the illustrative embodiment of the invention, a system for disabling a small boat comprises (1) two hulls, (2) a propulsion subsystem, (3) a homing, guidance, and control subsystem, (4) a depth-control subsystem, and (5) an entanglement device, typically comprising a long, stranded material that is neutrally or positively buoyant, suitably strong to be deployed by the moving hulls and not capable of being shredded by a prop.
[0007] The system, which is relatively small, is maintained aboard a commercial or naval vessel. If a small craft is detected by ships' crew or on-board sensors, and if it is determined or likely that operators of the small craft have malicious intent, the system is deployed in the water.
[0008] The homing, guidance, and control subsystem acquires the target and causes the propulsion subsystem to move the system toward the small craft. As the system nears the target, the entanglement device is deployed. The entanglement device is deployed by increasing the distance between the two hulls, thereby causing the net, etc., to spread out near the surface of the water.
[0009] The intent of the entanglement device is, as its name suggests, to become entangled with the target craft. As previously noted, the entanglement device is a neutrally or positively buoyant, long, stranded material. In some embodiments, the entanglement device is a neutrally or positively buoyant net of monofilament construction and includes a plurality of strands of fibrous material that extend from net. If the small craft is propeller driven, the net or strands become entangled with the prop or other protruding features of the craft. If the small craft is a jet boat, the strands of fibrous material will be ingested into the jet intakes. In either case, the small craft will be incapacitated and rendered motionless in the water.
[0010] Assuming that the small boat is disabled at an acceptable standoff distance (several hundred meters, etc.) from the ship, its mission will be frustrated. For example, in the case of attempted piracy, the pirates will be prevented from boarding and there will be ample time for the commercial ship to escape and radio for help. Or, if the encounter is with a naval vessel, the small boat will not be able to approach the hull to place explosives or perpetuate other acts of sabotage. And the naval vessel can respond as appropriate.
[0011] Since the system is non-lethal, it presents decreased safety risks for the crew. Furthermore, if the system is deployed against what turns out to be a non-hostile target, there will be no loss of life and any potential liability will be significantly reduced. The system is intended to be disposable, so a relatively minimal level of sophistication in terms of tracking, guidance, and control systems is desirable.
[0012] In some embodiments, the two hulls are small, unmanned underwater vehicles (“UUVs”). In such embodiments, the propulsion subsystem, homing, guidance, and control subsystem, depth-control subsystem (typically a ballasting system), and propulsion subsystem will be onboard each UUV.
[0013] In some other embodiments, one or both of the hulls is powered (i.e., propulsion hulls), but they are not autonomous in the sense of a UUV. In such embodiments, the two hulls are typically each coupled via movable linkages to a third hull, which can house the homing, guidance, and control subsystem. These embodiments incorporate a mechanism for reconfiguring the linkages, which changes the separation distance between the hulls to deploy the entanglement device.
[0014] In still further embodiments, the hulls are not powered; rather they are attached to a third hull that incorporates a propulsion subsystem and a homing, guidance, and control subsystem. The hulls typically include the depth-control subsystem (e.g., a ballasting system, etc.).
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 depicts system 100 in accordance with the illustrative embodiment for disabling small watercraft.
[0016] FIGS. 2A-2D depict system 100 of FIG. 1 in use.
[0017] FIGS. 3A-3D depict a first alternative embodiment of system 100 .
[0018] FIGS. 4A-4B depict a second alternative embodiment of system 100 .
[0019] FIG. 5 depicts a mother ship having under-the-waterline bays for deploying a system for disabling small watercraft in accordance with the illustrative embodiment of the present invention.
[0020] FIG. 6 depicts a method for disabling small watercraft in accordance with the illustrative embodiment of the present invention.
DETAILED DESCRIPTION
[0021] The illustrative embodiment of a system for disabling small watercraft comprises:
[0022] two hulls, wherein the separation distance between the hulls can be changed;
[0023] a way to propel and guide the hulls through water to a target;
[0024] an ability to float or submerge;
[0025] an entanglement device for disabling the target.
[0000] This system can be implemented in a variety of ways, a few of which are described herein and depicted in the accompanying drawings.
[0026] FIG. 1 depicts system 100 , which is first embodiment of a system for disabling small watercraft. In system 100 , the two hulls are realized as UUVs 102 A and 102 B. Entanglement device 108 is coupled to UUVs 102 A and 102 B.
[0027] UUVs 102 A and 102 B can be any one of a number of available UUVs, including, without limitation, Mk 39 EMATT, SUBMATT, as available from Lockheed Martin, or other suitable UUVs. Each UUV includes homing, guidance, and control subsystem 104 , depth-control subsystem 105 , and propulsion subsystem 106 .
[0028] In some embodiments, homing, guidance, control subsystem 104 comprises passive and/or active sensors for acquiring the small craft and a processor running software capable of estimating a trajectory of the small craft and/or an intercept trajectory. Having acquired the position of the small craft, the guidance system issues commands, for example, to the propulsion systems of UUV 102 A and 102 B to propel system 100 toward the target. It will be appreciated by those skilled in the art that any one of a number of approaches to acoustic tracking, guidance, and control can be used for homing, guidance, and control system 104 . It is within the capabilities of those skilled in the art to design and implement such systems.
[0029] In the illustrative embodiment, depth-control subsystem 105 is a conventional ballasting system, well known to those skilled in the art. Propulsion subsystem 106 comprises an electrically-driven propulsor or water jet, or other thrust-generating systems suitable for propelling UUVs, as a function of their size.
[0030] In accordance with the illustrative embodiment, entanglement device 108 comprises net 110 (e.g., monofilament, etc.) having fibrous “streamers” 111 extending therefrom. In some embodiments, streamers 111 comprise a plurality of elongated strands of fibrous material, each of which strands has a length that is typically in the range of about 1 to 4 meters. Entanglement device 108 need not be a net, per se; it can take any form that is suitable for disabling the propulsion system (e.g. entangling the propellers or other external features, fouling the intakes of a jet-propelled craft, etc.) of a target.
[0031] Operation of a system for disabling a small craft, such as system 100 , is now described in conjunction with FIGS. 2A through 2D and FIG. 6 .
[0032] FIG. 2A depicts small craft 220 approaching vessel 200 , which in this embodiment is depicted as being commercial shipping vessel 200 . A crew member aboard vessel 200 is alerted to the presence of craft 220 .
[0033] In response, the crew of the commercial vessel deploys system 100 into the water, as depicted in FIG. 2B . See also, FIG. 6 , operation 601 , which recites “deploying two hulls in the water.” In some embodiments, system 100 is simply lowered over the side of the vessel 200 . In some other embodiments, vessel 200 includes special adaptations for a more-stealthy launch of system 100 , such as a towing cradle, etc., that keeps system 100 submerged. Such adaptations, which can also include below-the-waterline storage bays (see, e.g., FIG. 5 ), would more typically be used in conjunction with a naval vessel.
[0034] Once in the water, acoustic sensors associated with system 100 acquire craft 220 and develop trajectory estimates and an intercept solution. See also, FIG. 6 , operation 603 , which recites “estimating a location of a target.”
[0035] System 100 then transits toward target 220 in accordance with trajectory/intercept estimates. See also, FIG. 6 , operation 605 , which recites “transiting the hulls to the target.” In a preferred mode of operation, system 100 dives to maintain stealth and then transits toward craft 220 .
[0036] As system 100 approaches target 220 , it surfaces. After surfacing, or just prior to surfacing, and in response to a command from a human operator or in accordance with system programming, UUVs 102 A and 102 B increase their separation distance, thereby deploying entanglement device 108 as depicted in FIG. 2C . See also, FIG. 6 , operation 607 , which recites “deploying an entanglement device by increasing a lateral separation between the two hulls.”
[0037] With entanglement device 108 deployed (e.g., net with streamers, etc.), system 100 engages target 220 , as depicted in FIG. 2D . The small craft becomes tangled in the net and the streamers snare the prop of the small craft or foul its jet intakes, whichever is present. See also, FIG. 6 , operation 609 , which recites “causing the entanglement device to become entangled with a portion of the target.”
[0038] In some further embodiments, more than one instance of system 100 is used. The use of a relatively larger number of these systems increases the potential reach of entangling device 108 and, of course, is required when the attacking force includes plural small watercraft.
[0039] FIGS. 3A through 3D depict system 300 , which is an alternative embodiment of system 100 depicted in FIG. 1 . One significant difference between system 300 and system 100 is that in system 300 , hulls 302 A and 302 B are not UUVs. At least one of hulls 302 A and 302 B is a propulsion hull (i.e., includes a propulsion subsystem), but neither of these hulls function autonomously in the manner of a UUV, such as UUVs 102 A and 102 B.
[0040] Referring now to FIGS. 3A through 3D , FIG. 3A depicts a front view of system 300 wherein entanglement device 108 is not deployed, FIG. 3B depicts the same view as FIG. 3A but with entanglement device 108 deployed, FIG. 3C depicts a side view of system 300 in the same state as in FIG. 3A , and FIG. 3D depicts a top view of system 300 in the same state as in FIG. 3B . For clarity, streamers 111 are not depicted in FIGS. 3A and 3B and the various linkages and other structure beneath entanglement device 108 are not depicted in FIG. 3D .
[0041] System 300 comprises hulls 302 A and 302 B, secondary hull 326 , linkages 312 A and 312 B, and entanglement device 108 , interrelated as shown.
[0042] With particular reference to FIGS. 3A and 3B , linkage 312 A couples hull 302 A to secondary hull 326 . Likewise, linkage 312 B couples hull 302 B to secondary hull 326 . As will be evident from FIG. 3C , system 300 includes two sets (one forward, one rear) of 312 A linkages (for coupling to hull 302 A) and two sets of 312 B linkages (for coupling to hull 302 B). Only the forward 312 A and 312 B linkages are depicted in FIGS. 3A and 3B and neither forward nor rear 312 B linkages are depicted in FIG. 3C .
[0043] In the embodiment of system 300 depicted in FIGS. 3A through 3D , linkages 312 A and 312 B are articulated or jointed. That is, pivot point 316 rotatably couples linkage member 314 to linkage member 320 and pivot point 322 rotatably couples linkage member 320 to secondary hull 324 .
[0044] Linkages 312 A and 312 B are capable of reconfiguring to change the separation distance between hulls 302 A and 302 B by allowing the linkage members to partially rotate relative to one another. Compare, for example, FIG. 3A to FIG. 3B ; the separation between hulls 302 A and 302 B is greater in FIG. 3B than in FIG. 3A . To achieve this increased separation, the angle between linkage member 320 and secondary hull 324 is increased and the angle between linkage members 320 and 314 is increased. And with the increased separation shown in FIG. 3B , entanglement device 108 deploys.
[0045] System 300 includes a mechanism or arrangement for reconfiguring linkages 312 A and 312 B. In the embodiment depicted in FIGS. 3A through 3B , the mechanism comprises spring-biasing devices 318 and 324 . The spring-biasing devices are arranged with respect to linkage members 314 and 320 such that in the absence of some restraint, device 318 causes member 314 to rotate away from member 320 . Device 324 causes linkage member 320 to rotate away from secondary hull 326 . In some embodiments, the restraint is a latch or similar mechanism (not depicted) that, when engaged, maintains linkages 312 A and 312 B in their “stowed” or non-extended state (as in FIG. 3A ). When homing, guidance, and control system 104 determines that system 300 is in the vicinity of the target and entanglement device 108 is to be deployed, the subsystem sends a signal to an actuator (not depicted) to move the latch, thereby freeing linkage members 314 and 320 . Once the linkage members are freed, the potential energy stored in spring biasing devices 318 and 324 can be released, resulting in the rotation of the linkages members, as previously described.
[0046] In conjunction with the present disclosure, those skilled in the art will be able to design and incorporate any one of a variety of mechanisms suitable for accomplishing the above-described functionality (i.e., reconfiguring linkages 312 A and 312 B). It is notable that for most contemplated uses, it is not necessary for linkages 312 A and 312 B to be able to autonomously return to their stowed after entanglement device 108 is deployed. After successful deployment and immobilization of a target, system 300 can be reset manually after recovery, to the extent recovery is desired. That is, with its relatively low cost, system 300 can be considered to be disposable.
[0047] FIG. 3A depicts system 300 fully submerged, which is optional if not preferable when transiting to a target (see, e.g., FIG. 6 : operation 605 of method 600 ). FIG. 3B depicts system 300 with hulls 302 A and 302 B and entanglement device 108 floating.
[0048] FIGS. 4A and 4B depict system 400 , which is a second alternative embodiment of system 100 depicted in FIG. 1 . A first primary difference between system 400 and system 300 is that in system 400 , neither hull 402 A nor hull 402 B is a propulsion hull. Rather, secondary hull 426 is a propulsion hull.
[0049] Referring now to FIGS. 4A and 4B , FIG. 4A depicts a side view of system 400 with entanglement device 108 not deployed and FIG. 4B a rear view with system 400 in the same state as in FIG. 4A . For clarity, streamers 111 are not depicted in FIG. 4A .
[0050] System 400 comprises hulls 402 A and 402 B, secondary hull 426 , two sets each of linkages 412 A and 412 B, and entanglement device 108 , interrelated as shown.
[0051] Linkages 412 A and 412 B function in the manner of linkages 312 A and 312 B, previously described. Hulls 402 A and 402 B depth-control subsystem 405 (e.g., ballasting system, etc.). Homing, guidance, and control subsystem 104 , and propulsion subsystem 106 are disposed in secondary hull 426 .
[0052] FIG. 5 depicts mother ship 500 . The mother ship includes under-the-waterline bays 530 A, 530 B, 530 C, and 530 D for stowing any of systems 100 , 300 , or 400 disclosed herein. In a threat condition, one or more of these systems can be deployed from ship 500 without alerting a target of the release.
[0053] It is to be understood that the disclosure teaches just one example of the illustrative embodiment and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the following claims. | A system and method for disabling a small boat comprises at least two hulls and an entanglement device disposed therebetween. In the illustrative embodiment, each hull is an unmanned underwater vehicle. The system is launched from a vessel to intercept the small boat. When close to the small boat, the separating distance between the two hulls is increased, thereby deploying the entanglement device and causing it to become entangled with the small boat (e.g., the small boat's propulsion system, etc.). | 1 |
CROSS-REFERENCES TO OTHER RELATED PATENT APPLICATIONS
[0001] The present application claims priority to U.S. provisional application Ser. No. 60/691,117 filed Jun. 17, 2005, all of which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] The invention generally relates to systems and methods used to facilitate commerce on computer networks as well as in commercial establishments. More particularly, embodiments of the claimed subject matter relate to online e-commerce in the field of vehicle aftermarkets.
SUMMARY
[0005] Embodiments of the claimed subject matter include systems and methods for facilitating commerce in the vehicle aftermarket, the systems and methods including the steps of allowing a user to select one or more items from a list presented to the user, associating the one or more items with at least one alias, mapping the one or more items into a preselected format and cataloging the mapped data so that it can be accessed by at least the user, so that the mapped data is integrated with a storefront so that the items may be located and sold using the mapped data.
[0006] Further aspects of the invention will become apparent from consideration of the drawings and the ensuing description of the several embodiments of the claimed subject matter. A person skilled in the art will realize that additional variations and embodiments of the claimed subject matter are possible and that the details of each of the embodiments can be modified in a number of respects, all without departing from the scope of the claimed subject matter. Thus, the following drawings and description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The features of the invention will be better understood by reference to the accompanying drawings which illustrate several embodiments of the claimed subject matter. In the drawings:
[0008] FIG. 1 is an overview according an embodiment of the claimed subject matter;
[0009] FIG. 2 is a diagram showing a commerce based embodiment;
[0010] FIG. 3 is a flow chart showing a prior art manual ordering process;
[0011] FIG. 4 is a flow chart showing an embodiment according to the claimed subject matter;
[0012] FIG. 5 is an image of a computer screen showing various advertising options of an embodiment according to the claimed subject matter;
[0013] FIG. 6 is an image of another computer screen displaying the addition of vehicle parts according to an embodiment of the claimed subject matter;
[0014] FIG. 7 is an image of another computer screen showing the assignment of characteristics to one or more parts in an embodiment of the claimed subject matter;
[0015] FIG. 8 is an image of another computer screen showing the assignment of related parts in a system according to an embodiment of the claimed subject matter;
[0016] FIG. 9 is an image of a computer screen for selecting parts in a system according to an embodiment of the claimed subject matter;
[0017] FIG. 10 is an image of a computer screen for editing a part in a system according to an embodiment of the claimed subject matter; and
[0018] FIG. 11 is an image of a computer screen for assigning an engine in an embodiment of the claimed subject matter.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0019] With reference now to the various figures in which identical elements are numbered identically throughout, a description of various exemplary aspects of the present invention will now be provided.
[0020] Referring now to FIG. 1 , a first embodiment of a system and method to facilitate commerce in the vehicle aftermarket is shown. This embodiment has been marketed as the MIGI™ eCommerce software solution by Digital Pages, Inc., doing business under several names including Digital Performance, Inc. This embodiment is an internet based embodiment although other embodiments can be implemented on other networks or without a network.
[0021] The present embodiment includes eCataloging and eCommerce elements and is comprised of two modules, now branded the MlCatalog and the MIStore. These modules allow vehicle data to be mapped to MIA industry standards and they allow the mapped data to be exported to online storefronts for creating and maintaining business applications such as retail to consumer and business-to-business applications.
[0022] Utilizing this embodiment, manufacturers, distributors arid retailers can centralize, own and maintain their product data in a format that is compliant or equal to AAIA's year-make-model engine industry standards. Other standards may also be used. In some embodiments, users may also release their mapped and/or cataloged data in order to keep customers and trading partners up-to-date, reducing product time-to-market. Users of the embodiments may also use the mapped and/or cataloged data to create and maintain one or more comprehensive retail or B2B online storefronts, complete with dealer and price level management, multiple search methods, order history and sales reports.
[0023] Users such as manufacturers and distributors can also publish their product data to centralized information storehouse web sites or platforms, such as the one maintained at the internet web site StreetPerformance.com, so their products may be found by consumers and businesses seeking aftermarket products and services. The product data may also be integrated into the user's own product search algorithms and methods on the user's own systems and web sites.
[0024] The visual presentation of the electronic product assists the user and consumers in searching for one or more parts by various fields. These fields include the year-make-model, engine, and part catalog number. These fields can be adapted to the user's individual requirements such as the company number, keywords and/or categories. The data can be easily adapted to be used across more than one e-commerce platforms.
[0025] Web sites can use the data with a variety of other web site components, such as a secure server shopping cart and database systems such as MySQL or an Oracle database solution. The present embodiment include the following features and component interface screens: Orders Admin, Order Administration, Shipping Administration, Credit Card Administration, Parts Admin, Configure, MlStore, Editing a new or existing Company, Car Makes, Categories, Attributes, Parts, Adding One Part Adding Multiple Parts, Editing Parts, Vehicles, Assigning V-M-M, Assigning Engines Assign, Assigning Categories, Assigning Attributes, Assigning Weights/Actual Shipping, Pictures, Assigning Pictures to a Part, Uploading Pictures, Footnotes, and Assigning Footnotes to a Part, Adding a Footnote, Editing a Footnote, Deleting a Footnote, Assigning Universal Parts, Assigning Kits to Parts, Assigning Related Parts, Global Updates, Pricing, Weights—File Upload, Home Page, Products, Featured Parts, Customizing Homepage with Product Specials, Removing a Product Special, Home Page Categories, Featured Categories, Configuring Categories to Products Removing a Company, Assigning an Image to a Category, Home Page HOT BUYS, Assigning HOT BUYS, Removing HOT BUYS, Home Page Pictures, Uploading Pictures to the Homepage, Content Manager, Featured Article/Tech Article/News Item Creating an Article, Editing an Article, Promotions Admin, Coupons, Creating a New Custom Coupon, Editing an Existing Coupon, Bulk Emails, Send a Bulk Email, Private Label Admin, Assigning Private Label Parts, Editing a Private Label Part, Deleting a Private Label Part, Categories Admin, Edit a Parent Category, Add a New Category, Suppliers Admin, Suppliers Administration, Adding New Suppliers, Editing Suppliers, Dealer Admin, Price Levels, Adding a Price Level, Editing a Price Level, Dealers, Adding a New Dealer, Editing a Dealer, and Deleting a Dealer.
[0026] Other features and component interface screens include Assigning Levels/Discounts, Assigning Price Levels, Assigning Payment Methods, Adding a Product line Discount, Removing a Product line Discount, Shopping Cart Report, Viewing Top Selling Companies, Viewing Parts Sold, and Review and Export Data.
[0027] In the Order Administration area, orders may be viewed, edited, or deleted using various features and component interface screens including Quick Search, for example using variables of first name, last name and order number, Input query, i.e. name or order number which can be found in the query box so that records can be retrieved or pulled up based on the specific query. A “Go” button may also be included to complete one or more functions.
[0028] The View Orders function includes features to view one or more orders according to the order type. For example, the order type can be: Cancelled, Closed, Open, Return Pending, and Returned. The order list may also be sorted by the Sort Orders feature. This feature allows a user to select how a list is sorted by choosing a type of field to be sorted upon. For example, order number, last name or the order date fields.
[0029] The details of these as well as other features of the multiple embodiments are describes below in outline format.
[0030] Order Administration
[0031] To view, edit, or delete orders, simply use one or more of the following options.
[0032] Quick Search (first/last/name/order#)
[0033] Input query—i.e. name or order number—in the box to pull up records based on the specific query. Press “Go” button to complete.
[0034] View Orders
[0035] Views order according to type: Cancelled, Closed, Open, Return Pending, Returned. Select type and press the “Go” button to the right.
[0036] Sort List By
[0037] Select how list is sorted by choosing a type—Order #, Last Name or Date—and pressing “Go.”
[0038] To ADD Credits or Extra Charges
[0039] Step 1: Select the Order that needs to be changed.
[0040] Step 2: In the field labeled: “Reason for Change,” enter reason.
[0041] Step 3: Enter the amount to be credited or charged in the appropriate fields.
[0042] Step 4: Press the appropriate button—“Credit” to credit account, “Charge” to charge account—to complete transaction.
[0043] To CHANGE Order Status
[0044] Step 1: Select the Order that needs to be changed.
[0045] Step 2: In the field labeled: “Reason for Change,” enter reason.
[0046] Step 3: Select the appropriate status (Cancelled, Closed, Open, Return Pending, Returned) from the pull down menu.
[0047] Step 4: Press “Update” to complete transaction.
[0048] Shipping Administration
[0049] To View Open Orders by Company
[0050] Select the link for the appropriate company.
[0051] To Change the View of Orders to See Cancelled, Closed, Open, Return Pending, or Returned.
[0052] Select the view you want to see from the pull down menu at the top of the page, and press “Orders”.
[0053] To Update Orders
[0054] Step 1: Select appropriate changes:
SHIPD for Shipped EMAIL for Email To select Shipping Company, select the correct company from the pull down menu. Enter the Tracking # in the specified field. To enter “NOT SHIPPED/REASON” “EST SHIP DATE” or “REDIRECT ITEM” select the appropriate reason from the pull down menu.
[0060] Step 2: Press “UpdateOrders” to complete transaction.
[0061] Credit Card Administration
[0062] When a user clicks on the “credit card admin” link, a new window will pop up with the VeriSign Manager and the user can login using the user's Merchant Login and Password to make any changes using the VeriSign Manager.
[0063] To Change the View of Orders to See Cancelled, Closed, Open, Return Pending, or Returned:
[0064] Select the view you want to see from the pull down menu at the top of the page, and press “Orders”.
[0065] To Update Orders:
[0066] Step 1: Select appropriate changes:
SHIPD for Shipped EMAIL for Email To select Shipping Company, select the correct company from the pull down menu. Enter the Tracking * in the specified field, To enter “NOT SHIPPED/REASON” “EST SHIP DATE” or “REDIRECT ITEM” select the appropriate reason from the pull down menu.
[0072] Step 2: Press “UpdateOrders” to complete transaction.
[0073] Credit Card Administration
[0074] When a user clicks on the “credit card admin” link, a new window will pop up with the VeriSign Manager. Once the user has logged in using the user's login and password, the user can make any desired changes. The following includes features related to the Parts Admin module:
[0075] If more than one vendor is present, the user can select the company that the user wants to edit by choosing from the pull down menu in the left column. If the user desires, he or she can edit an entire category by selecting the category from the pull down menu in the left column.
[0000] Configure
[0076] Customizing MIStore
Step 1: Enter Contact Information in the appropriate fields. Step 2: Select the features that you would like on MIStore. Step 3: Enter Home Page Name and Click the “Next” button. Step 4: To upload your header image, click on the “Browse” button to select a file on your computer. Locate the image in your computer and click on the “Open” button. (The header must be 749 pixels wide×108 pixels high, if your header exceeds these dimensions, please use a photo editing program to crop the image to size). Step 5: Choosing Colors
Click on the icon with the artist's palette to view the color menu, click on the color that you want for each of the color options. Template Color 1 is the background color behind the text. Template Color 2 is the accent color bar next to the text background color. Background Color is the color that goes behind everything on the entire page. Font Color is the color of the header texts. To select a background pattern, simply select the pattern that you want. This pattern will be laid over the background color. Click on “Preview” to preview color combination.
Step 6: Fill in the title names for each of the sections. Step 7: Company Description
Input Company Keywords: These keywords will help you get listed high on the search engines. Keywords include the products you sell and/or industry you are in. Input Company Description: This is a brief description of your company; it will be in the Meta tag and MIStore page. Descriptions include something about your company and/or the services that you provide. Input Title: This is the title that you would like for your pages. This should include your company name and a few keywords.
Step 8: Searches
Select type of searches you would like on your MIStore by clicking on the search category you would like.
Step 9: Uploading Logo and Slogan Images
1. To upload an image click on the “Browse” button. 2. Locate the image on your computer that you want for your logo and tag. 3. Click “Open.”
Step 10: Click on the “Submit” button to complete changes.
[0103] Editing a Company
To Add a Company Fill in the company's name in field named: “Company Name” and press the “Add” button. To Edit or Delete a Company
Step 1: Select a company from the pull down menu at the top of the Parts Admin menu, click on the “edit/delete company” link. Step 2: On the right side of the window, you will be able to make edits to the company name, description and changes in logo. Step 3: To update company info, simply make the necessary changes to the information and click the “Update Company Info” button. Step 4: To delete company info, simply click on the “Delete Company” button. Step 5: To change the logo click on the “Browse” button and locate on your computer the new image that you want to use and click the “Open” button. Click on the “ADD New Pictures” button to complete the upload. Note: Large logos must not exceed 100 pixels wide and small logos must not exceed 45 pixels wide, please use a photo editing program to crop any images larger than these dimensions.
[0113] Car Makes
To Configure Models
Step 1: Select a make or makes from the menu Note: Selecting multiple companies here will slow MIGI down. Step 2: Click on “Update.” Step 3: Highlight the part number(s) in the left table and highlight the model(s) in the right table. To select more than one number or model at a time, press the Control [Ctrl] key while clicking on the item you want to select. If you wish to select groups of numbers or models, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 4: Click on “Assign.”
[0121] Categories
To Assign a Category to Your Product Select a category or categories from the menu that applies to your products and click on “ADD” to assign them. Do a Quick Search by inputting a category in the field and clicking on the “Quick Search” button. To select multiple categories, hold down the Control [Ctrl] button while selecting. If you wish to select groups of categories, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. To Remove a Category Simply click on the “[remove]” link to the right of the category.
[0126] Attributes
To Add a Value to an Existing Attribute Select an attribute from the left table and enter new values in the boxes below and click on the “Add” button. To Add a NEW Attribute
Step 1: Will the values for this new attribute be TEXT or NUMERIC? Select the option for the value you want. Step 2: Fill in the Attribute's Name. Step 3: If a Unit of Measure is applicable, select the appropriate option from the dropdown menu. Step 4: To enter the Attribute Values, type the values in the fields under “Attribute Values.” Step 5: Click on the “ADD ATTRIBUTE” button.
Listed attributes cannot be deleted.
Parts
[0135] Adding/Editing Parts
To Add One Part
Step 1: Simply enter the details in the applicable fields. Step 2: To load an image to represent the item:
1. Click on “Browse” button; locate the image on your computer and click “Open.” A Thumbnail picture is a small fast loading image. It should not exceed 130 px wide, if it should, please use a photo editing program to crop the image to size. A Large Picture is a larger more detailed, but slower loading, image of the product. It should not exceed 450px wide, if it should, please use a photo editing program to crop the image to size. 2. Click on and highlight the appropriate category for the part. 3. Click on “CONTINUE.”
To Add Multiple Parts
Step 1: Format an Excel Spreadsheet according to these specifications:
Column A—Part # Column B—Description Column C—Retail Price Column D—Jobber Price Column E—Cost Price Column F—WD Price Column G—Weights Column H—OEM/Alternate Part # Your data may look similar to the following:
[0155] Table 1 shows an example of an entry related to the fields described in Step 1 above:
TABLE 1 A B C D E F G H 1 100A Brake Pads for Nissan 300ZX 300.00 225.00 179.00 150.00 10.00 oem2343 . . .
Remove any Commas in the data as they sometimes interfere with the load (In Excel go to Edit>Replace . . . and put in a comma in the top and nothing in the bottom and click “Replace”). If you have less than 5 columns, enter a 0 at the top of each of the empty columns to prevent any problems. Make sure there are no descriptions in the header describing the fields. The first row of the Excel sheet must contain data for the first part. Step 2: Save the worksheet in Excel format and close the document. Step 3: Upload the Excel file Click on “Browse” and locate the appropriate file on your computer. Click on “Open.” If you want to overwrite the current descriptions of existing products, click on the box to select it. Step 4: Click on “Next.” Check to see that the data uploaded is correct. If something is incorrect, try to modify the Excel Spreadsheet, save it and re-upload the file to MIGI. Step 5: Click on “Upload Data into System” to complete changes in MIGI.
[0166] Edit Existing Parts
Step 1: Select the part(s) you want to edit and click on “EditParts.” To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”. To sort the Makes & Models list, use the box above the table containing all the models. Enter the start year and end year, select an option from the “Show” and/or “Vehicle” pull down menus and press “GO”. To select multiple part numbers at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of parts, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 2: Make any necessary edits in the next screen and click on “GLOBAL UPDATE.”
[0173] To DELETE a part
Step 1: Highlight the part(s) you want to delete and click on “DELETEParts.”
[0175] FIGS. 7 through 11 are images of computer screen showing various features of embodiments of the claimed subject matter. As shown in FIG. 7 and similarly in FIGS. 8 through 11 , the following steps are shown:
Step 1: Choose the part(s) you want to assign.
To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT.” To select multiple part numbers at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of parts, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups.
Step 2: Select the part's corresponding Make & Model
To view select cars makes and models, do one or more of the following:
Enter a Start and End Year Select a Make from the dropdown menu. Clicking on the “EDIT” link pops up a new window in which you can select from a menu of car makes. Make your selection(s), click on “UPDATE” close the popup window, and click on the “(refresh)” link to show changes. Select a Vehicle option from the dropdown menu. Click “GO” to sort.
Step 3: Click “ASSIGN. As shown, the * indicated that the part needs to be assigned. (Example: 19200: 1999-2004 GMC Sierra [1000|*] This part still needs a picture to be assigned.)
Attributes
[0188] To Assign an Attribute
Step 1: Select the part(s) you want to assign To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”. To select multiple part numbers at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of part numbers, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 2: Select the corresponding attribute(s). Step 3: Click on “ASSIGN.” Legend: *=Needs to be assigned. (Example: 19200: 1999-2004 GMC Sierra [1000|*] This part still needs a picture to be assigned.)
[0196] Weights/Actual Shipping
[0197] To assign weights/actual shipping
Step 1: Select the part(s) you want to assign. To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”. To select multiple part numbers at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of part numbers, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 2: Enter the Weight and/or Actual Shipping (applies to certain distributors) and click on the button below the field. Legend: *=Needs to be assigned. (Example: 19200: 1999-2004 GMC Sierra [1000|*] This part still needs a picture to be assigned.)
[0204] Pictures
[0205] To Assign Pictures
Step 1: Select the part(s) you want to assign. To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”. To select multiple part numbers at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of part numbers, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 2: Enter the Weight and/or Actual Shipping (applies to certain distributors) and click on the button below the field. Step 3: Click on “ASSIGN”
[0212] To Upload Pictures
Large Pictures may not exceed 450px wide, and small picture may not exceed 130px wide if it should, please use a photo editing program to crop image to size. Step 1: Click on the “Browse,” locate and highlight the image on your computer and click on “Open.” Step 2: Click on “ADD New Pictures.” Legend: *=Needs to be assigned. (Example: 19200: 1999-2004 GMC Sierra [1000|*] This part still needs a picture to be assigned.)
[0217] Footnotes
[0218] To Assign a Footnote to a Part
Step 1: Click on the part(s) that you want to assign. To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”. To select multiple part at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of parts, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 2: Click on its corresponding footnote and click on “ASSIGN.”
[0224] To ADD a Footnote
Step 1: Simply type or copy and paste the new footnote into the field at the bottom of the page. Note: You may use HTML code within your footnote. The code to link to an outside document (i.e. a PDF or another website) is <a href=“[document name or website address]”>[insert the link name]</a> Make sure to remember to have the </a> at the end of your link as this closes the tag. Step 2: Click on “NEW FOOTNOTE.”
[0230] To EDIT a Footnote
Step 1: Highlight the footnote and click on “EDIT.” Step 2: Make your changes and click on “SAVE.”
[0233] To DELETE a Footnote
Step 1: Highlight the footnote Step 2: Click “DELETE.”
[0236] “Universal” Parts
[0237] To Assign “Universal” Parts
Step 1: Click on the part(s) you want to assign. To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”. To select multiple parts at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of parts, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 2: Click “ASSIGN UNIVERSAL”. Legend: *=Needs to be assigned. (Example: 19200: 1999-2004 GMC Sierra [1000|*] This part still needs a picture to be assigned.)
[0244] Kits
[0245] To Assign Kits to Parts
Step 1: Click on an existing part number to create a kit. To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”. To select multiple part numbers at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of part numbers, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 2: Click on the parts related to kit.
To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”.
Step 3: Click on “ASSIGN.”
[0254] Related Parts
[0255] To Assign Related Parts
Step 1: Select the part(s) you want to assign. To find a specific part by part number, simply enter the part number in the field and press the “GO” button. To sort the parts list by Description, Part # or Category, simply select the order in which you want the list sorted and click on “SORT”. To select multiple part numbers at a time, hold down the Control key [CTRL] while selecting. If you wish to select groups of part numbers, simply highlight the first group and then hold down the Control [Ctrl] to select additional groups. Step 2: Select Manufacturer from the pull down menu. Step 3: Enter Part Number. Step 4: Repeat for additional parts. (If applicable). Step 5: Click on “ASSIGN.”
Global Updates
[0264] Pricing
Format an Excel spreadsheet with the following guide instructions. Make sure the pricing does not have commas or dollar symbols (to format this in Excel, go to Format>Column>Number [with 2 decimals]). Step 1: Format the data as follows:
Column A—Part # Column B—Racer Price (Retail) Column C—Jobber Column D—Stocking Jobber Column E—WD Price Column F—Master WD (MWD) Price
[0274] Your data should look similar to the following Table 2:
TABLE 2 A B C D E F 1 100A 300.00 225.00 179.00 150.00 100.00 . . .
Note: Make sure there are no descriptions in the header describing the fields. The first row of the Excel sheet must contain data for the first part. Step 2: Save the Excel spreadsheet by going to File>Save As Save the worksheet as a CSV (comma delimited) file—you can find this option by clicking on the pull down menu for “Save as type” and selecting CSV (comma delimited). Step 3: Upload the CSV file to MIGI. To upload file, click on the “Browse” button in Step 5. Locate the saved CSV file on your computer and click on the “Open” button (Do NOT upload the Excel file!) Step 4: Click on the “Submit” button to upload changes.
[0281] Weights—File Upload
To update weights, format an Excel spreadsheet with the following guide instructions. (Note: These instructions are different than the instructions for Pricing changes!) Step 1: Format the data as follows:
Column A—Part # Column B—Weights Column C—Actual Shipping Column D—Dimensions (H×L×W) Column E—Unit of Measure (inch, ft, cc, cm) Column F—UPC Code
[0290] Your Data should look similar to the following table:
TABLE 3 A B C D E F 1 100A 12.00 20.00 10 × 10 × 2 inch UPC102342404 . . .
Be sure to remove all Commas to avoid any problems. (You can do this quickly by going to Edit [in the toolbar]>Replace to find all the commas and delete them out). Note: Make sure there is something in the first cell of each column. If there is a column you are not using, put a 0 in the first cell. Also, make sure there are no descriptions in the header describing the fields. The first row of the Excel sheet must contain data for the first part. Step 2: To save the Excel spreadsheet, go to File>Save As Save to worksheet in Excel Format, it should the default file type that Excel saves to. Step 3: To upload the Excel file, click on the “Browse” button, locate the file on your computer, and click on “Open” button. Step 4: Click on the “Next” button to continue.
Home Page Products
[0297] Featured Parts
[0298] Customizing Homepage with Product Specials
Step 1: From the “All Products Available” menu, select the part(s) that you want to assign Product Specials. Step 2: Click on “ASSIGN PRODUCTS.”
[0301] Removing a Product Special
Step 1: Select the Part you want to remove from the “Currently Selected Products” menu. Step 2: Click on “RLMOVEPL.”
Home Page Categories
[0304] Featured Categories
[0305] Configuring Categories to Products
Step 1: Select an available category. Step 2: Select a product. Step 3: Click “ASSIGN CATEGORIES.”
[0309] Removing a Company
Step 1: Click on the company you want to remove. Step 2: Click “REMOVE COMPANIES.”
[0312] Assigning an Image(s) to Go With a Category
Step 1: Click “Browse” Step 2: Locate and select the image you want to use on your computer. Step 3: Click “Open.” Step 4: Click “Assign Categories.”
Home Page HOT BUYS
[0317] Assigning Hot Buys
Step 1: Select the product that you want to assign as a “Hot Buy.” Step 2: Click on “ASSIGN HOT BUY.”
[0320] Removing Hot Buys
Step 1: Select the Hot Buy you want to remove. Step 2: Click on “REMOVEPL.”
Home Page Pictures
[0323] Uploading Pictures to Home Page
Step 1: Click on the “Browse” button on the right hand side of the page. Step 2: Locate where the image is on your computer and press the “Open” button. Images should be no larger than 450 pixels wide with a resolution of 72 dpi, if it exceeds this width and resolution, use a photo editing program to crop the picture to size. Step 3: In the “URL to point Picture” field enter the URL that you want this picture to link to. (If Applicable). Step 4: To complete upload, click on the “ADD New Pictures” button.
Content Manager
[0329] Featured Article/Tech Article/News Item
[0330] Creating an Article
Step 1: Select which type of article you would like to create by clicking on the link in the menu on the left hand side of the MIGI program. Step 2: Input Article Title. Step 3: Upload picture(s). Step 4: Type or copy and paste in Article Text. This window works similar to a Word Document. To change the font, font size, justification, font color, etc., use the tool bar directly above the content window. Step 5: Click on “SUBMIT.”
[0337] To EDIT an Article
Step 1: Select the article you want to from the dropdown menu. Step 2: The article should appear in the window, make changes and click on “SUBMIT”.
Promotions Admin
[0340] Coupons
[0341] Creating a New Custom Coupon
Step 1: Select the Type of Coupon from the dropdown menu. Step 2: Enter Specific Part Number (If product specific). Step 3: Enter Coupon Number. Step 4: Select the Coupon Amount Type from the dropdown menu. Step 5: Enter the Percent Off (If Percent Off).—Do not use decimals. Step 6: Enter Amount Off (If Specific Amount Off). Step 7: Enter Expiration Date. Step 8: Click “create.”
[0350] Editing an Existing Coupon
Step 1: Selecting the coupon you want to edit from the pull down menu. Step 2: Click the “edit” button. Step 3: Make any edits and save the coupon.
[0354] Bulk Email
[0355] To Send Bulk Email
Step 1: Enter who the email is from in the “From:” field. Step 2: Enter the Subject Step 3: Upload an image for header
To upload an image:
1. Click on the “Browse” button. 2. Locate and select on your computer where the image is. 3. Click on the “Open” button. 4. Click on the “Upload” button.
Step 4: Type or paste the body of your email into the “Email_Content”. To change the font, font size, justification, font color, etc., use the tool bar directly above the content window. Step 5: Click on “Preview” to preview your email. Step 6: If you have any changes, click on the “Edit” button. Make any necessary edits and save. Step 7: Click on the “Email” button to send the email out to list.
Private Label Admin
[0369] Assigning Private Label Parts
Step 1: Select a company from the pull down menu on the left hand side of the screen and click on the “assign specialty parts” link below. Step 2: Enter Part Number and press “Go.”
In the “Part# Description” section you can sort the parts by “Description”, “Part#”, and “Category” by selecting the option you want and pressing the “Sort” button.
[0373] Editing a Private Label Part
Step 1: Highlight the part you want to edit and click on the “EditParts” button. Step 2: The next screen should have a table where you can edit the Part#, Description, Weight, etc. Make your changes here. Step 3: Press the “GLOBAL UPDATE” button to save changes.
[0377] Deleting a Private Label Part
Step 1: Highlight the part you want to delete and click on “Delete Parts”. Step 2: You will go to a page that will ask to confirm if you want to delete the part, click on the button to confirm and delete.
Categories Admin
[0380] Category Administration
[0381] To EDIT a Parent Category
Step 1: Select the category from the pull down menu and click on “Edit.” Step 2: In the “Category Maintenance Screen”, make any changes. Step 3: To add a category to the level enter the category and click on “ADD”. Step 4: When changes are complete, click on “update” to continue.
[0386] To ADD a New Category
Step 1: Enter AAIA_ID and the category name. Step 2: Click “ADD.”
Suppliers Admin
[0389] Suppliers Administration
[0390] To Edit Companies or Parts
Step 1: Click on the company name link to open up an “Order Administration Screen.” In this screen you can assign IDs or Card Codes to the individual company. Click on “ReAssign” to complete changes. Step 2: Click on the “edit” button to edit part numbers.
To Edit a Single Part Number Enter the part# and press “Go.” To Edit Multiple Part Numbers Either do a search by part numbers, or sort the list by category choices. To Select More Than One Part Hold down the Control [CTRL] button on the keyboard while you click on the parts you want to highlight. Click on the “EditParts” button to make your changes, click on “DELETEParts” to delete parts.
[0399] Company Segments
[0400] To View Company Segments
Step 1: Click on the link for “company segments.” Step 2: To view or change company data, click on the company name. Step 3: Enter any altered data and click on “ReAssign” to update. Step 4: To change active status, click on the appropriate link.
[0405] Category Segments
[0406] To View Category Segments
Step 1: Click on the link for “category segments.” Step 2: Click on the category link. Step 3: Make any changes in the screen. Step 4: For changes in Category names, simply click on the link of the category that you want to change and make any edits in the next screen. Step 5: Click “Add” to update
[0412] Suppliers
[0413] Adding New Suppliers
Step 1: Select a manufacturer from the pull down menu and click “ADD.”
[0415] Editing Suppliers
Step 1: Select a manufacturer from the pull down menu and click “EDIT.” Step 2: In the next screen, make any necessary changes and click “UPDATE.”
Dealers Admin
[0418] Price Levels
[0419] Adding a Price Level
Step 1: Input Price Level (e.g., Stocking jobber, etc.). Step 2: Input Percentage off. Step 3: Select which price option from the pull down menu. Step 4: Click on “ADD PRICING.”
[0424] Editing Price Level
Step 1: Select the price level you want to edit from the pull down menu and select “EDIT” to edit or “DELETE” to delete. Step 2: Make any necessary changes in the Edit window and click “UPDATE.”
[0427] Dealers
[0428] Adding a New Dealer
Step 1: Click on the link that says “Add a New Dealer.” Step 2: The next screen will have fields for you to fill out. Enter the appropriate information in the fields. Step 3: Click on “ADD DEALER.”
[0432] Editing a Dealer
Step 1: Select a dealer from the pull down menu and click on the “EDIT” button. Step 2: In the next screen, make any necessary changes and click on “UPDATE DEALER.”
[0435] Deleting a Dealer
Step 1: Select a dealer from the pull down menu. Step 2: Click on “DELETE DEALER” to remove this dealer from database.
[0438] Assigning Levels/Discounts
[0439] Assigning Price Levels
Step 1: Select the Dealer that you want to assign price to. Step 2: Select the Price Level. Step 3: Click on “Assign.”
[0443] Assigning Payment Methods
Step 1: Select the Dealer. Step 2: Select the Payment Method. Step 3: Click on “Assign.”
[0447] Adding a Product Line Discount
Step 1: Select the Dealer. Step 2: Enter the percentage off and select the price from the dropdown menu. Step 3: Select the Product Line. Step 4: Click on “Assign.”
[0452] Removing Product Line Discounts
Step 1: Select the product line discount. Step 2: Click on “REMOVE.”
Shopping Cart Reports
[0455] Companies
[0456] Top Selling Company
Step 1: To view the top selling company, click on the link that reads “top selling companies.” Step 2: Copy and Paste data into an Excel Spreadsheet to manipulate the data better.
[0459] Parts Sold
Step 1: To see what parts have been sold, click on the link that reads “parts sold.” On the next page, a chart appears containing all the data of the parts sold, sorted by company name.
Review & Export Data
Step 1: To export data, click on the appropriate link for the information that you want to export. Step 2: A File Download window will appear, click on “Open” to open the file directly in an Excel window, click on “Save” to save the file to disk—your computer or a floppy, etc.
[0464] While the embodiments have been described with reference to specific features and elements in various configurations, it should be understood by those skilled in the art that various changes and modifications may be made and equivalents may be substituted for elements thereof without departing from the scope of the claimed subject matter. Therefore, the claimed subject matter is not limited to the various disclosed embodiments including the best mode contemplated for carrying out the claimed subject matter, but instead includes all possible embodiments falling within the scope of the appended claims. | A system and method for facilitating commerce, the system and method including the steps of allowing a user to select one or more items from a list presented to the user, associating the one or more items with at least one alias, mapping the one or more items into a preselected format and cataloging the mapped data so that it can be accessed by at least the user, so that the mapped data is integrated with a storefront so that the items may be located and sold using the mapped data. | 6 |
This application is a continuation of application Ser. No. 081783,224, filed Jan. 14, 1997, pending.
FIELD OF THE INVENTION
The invention relates to the reaction products of alkoxylated alcohols and epichlorohydrin and their use of alkoxylated alcohols to control foaming in surfactant compositions.
BACKGROUND OF THE INVENTION
Aqueous cleaning compositions exhibit a tendency toward foaming because they contain surface active agents such as soaps, and synthetic detergents. In many instances, such cleaning compositions produce excessive foam and the user must use substances known as add anti-foaming agents or defoamers. Some defoamers such as silicones tend to interfere with the function of the cleaning compositions in that unwanted residues are left after the cleaners are wiped off while others are environmentally unacceptable because they are not biodegradable.
Alkyl polyglycosides are a class of nonionic surfactants that exhibit significantly higher foaming profiles than other nonionic surfactants, such as alcohol ethoxylates. In fact, it can be said that the foaming tendencies of alkyl polyglycosides more closely resemble those of anionic surfactants, such as alcohol sulfates, than the foaming tendencies of other nonionic surfactants. This higher foaming tendency makes the use of alkyl polyglycosides undesirable for many applications, e.g. cleaning-in-place for food processing plants, high pressure spray cleaning, bottle washing, floor cleaners and automatic dishwashing, wherein high levels of foam interfere with the cleaning and rinsing operation and reduce the efficiency of the operation.
Low foam nonionics, such as EO/PO block copolymers, can be used to reduce the foaming properties of alkyl polyglycoside surfactants, but these materials have undesirable properties, e.g. low biodegradability, relatively high aquatic toxicity and poor caustic compatibility.
Accordingly, there is a need for the development of defoamers that do not interfere with the cleaning ability of aqueous cleaning compositions and that are biodegradable, exhibit low aquatic toxicity and good caustic compatibility.
SUMMARY OF THE INVENTION
The surprising discovery has been made that the products of the reaction of epichlorohydrin and compounds having the formula II
R.sub.3 (EO).sub.n (PO).sub.m --OH (II)
wherein R 3 is an alkyl, alkenyl or arenyl group having from 4 to 22 carbon atoms; a substituted alkyl or alkenyl group having from 4 to 22 carbon atoms wherein; n is a number from 0 to 50 and m is a number from 0 to 10; wherein the mole ratio of epichlorohydrin to (II) is from about 0.60/1 to about 2/1 are extremely efficient defoamers for aqueous surfactant systems. These reaction products are added to a surfactant in an amount sufficient to reduce or eliminate foam. The reaction products have the advantage of being totally dispersible in water, are readily biodegradable, contain no organic solvents and do not affect the detergency of surfactants with which they are used because they are nonionic surfactants in themselves.
DESCRIPTION OF THE DRAWING
The FIGURE shows the relative defoaming effect of 0.1% by weight of a defoamer from Examples 1-3 on GLUCOPON® 220 Surfactant in soft water at 25° C. under the test protocol of Example 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The defoamers according to the invention are reaction products as described herein below and are added to a surfactant-water system comprised of one or more surfactants in an amount effective to eliminate or decrease the foam generated by the surfactant as a result of some type of mechanical action such as mixing, pouring, and/or shaking. The amount required to eliminate and/or decrease foam is defined as a defoaming effective amount and will vary from one instance to another depending upon the nature of the surfactant or mixture of surfactants and the defoaming effect desired. A defoaming effective amount will be readily determinable by one of ordinary skill in the art. When the surfactant is one or more alkyl polyglycosides, the defoaming effective amount will typically vary from a weight ratio of alkyl polyglycoside/defoamer 4.0/1.0 to about 1.0/1.0.
The defoaming compositions according to the invention are the products of the reaction of epichlorohydrin and compounds having the formula II
R.sub.3 (EO).sub.n (PO).sub.m OH (II)
wherein R 3 is a substituted or unsubstituted, saturated or unsaturated aliphatic moiety having from 4 to 22 carbon atoms; a substituted alkyl or alkenyl group having from 4 to 22 carbon atoms wherein; n is a number from 0 to 50 and m is a number from 0 to 10; and epichlorohydrin wherein the mole ratio of epichlorohydrin to (II) is from about 0.60/1 to about 2/1 and preferably from about 0.80/1 to about 2/1.
In regard to the alkoxylates of formula II, R 3 can be any substituted or unsubstituted, saturated or unsaturated aliphatic moiety having from 4 to 22 carbon atoms. Thus R 3 can be a linear or branched alkyl group, a linear or branched alkenyl or alkenyl group, a saturated carbocyclic moiety, an unsaturated carbocyclic moiety having one or more multiple bonds, a saturated heterocyclic moiety, an unsaturated heterocyclic moiety having one or more multiple bonds, a substituted linear or branched alkyl group, a substituted linear or branched alkenyl or alkynyl group, a substituted saturated carbocyclic moiety, a substituted unsaturated carbocyclic moiety having one or more multiple bonds, a substituted saturated heterocyclic moiety, a substituted unsaturated heterocyclic moiety having one or more multiple bonds. Examples of the above include but are not limited to an alkyl group having from 4 to 22 carbon atoms, an alkenyl group having from 4 to 22 carbon atoms, an alkynyl group having from 4 to 22 carbon atoms. R 3 can also be an arenyl group. Arenyl groups are alkyl-substituted aromatic radicals having a free valence at an alkyl carbon atom such as a benzylic group. The preferred value of R 3 is an alkyl group having from 4 to 22 carbon atoms and most preferably an alkyl group having from 8 to 10 carbon atoms. The degree of ethoxylation is preferably from 2 to about 50 with the most preferred being from about 4 to about 50 while the degree of propoxylation can vary from 0 to 10. The degree of propoxylation will be determined by the desired degree of water solubility or miscibility. The water solubility or miscibility will ultimately be determined by such factors as the number of carbon atoms in R 3 , the relative amounts EO to PO and the effect of PO on the biodegradability of the final defoamer. The water solubility or miscibility of a defoamer according to the invention and the interrelationships between the number of carbon atoms in R 3 , the relative amounts EO and PO and the biodegradability of the final product will be readily determinable by one of ordinary skill in the art.
The reaction products of the alkoxylates of formula II and epichlorohydrin are described in copending application Ser. No. 08/727,983, filed on Oct. 9, 1996, now U.S. Pat. No. 5,728,895, the entire contents of which are incorporated herein by reference and can be made by the procedure set forth in the Examples below.
While the method according to the invention can be used to control foam generated by any type of surfactant or blend of surfactants, it is especially useful for controlling foam in compositions containing one or more alkyl polyglycoside surfactants.
The alkyl polyglycosides which can be used in the invention have the formula I
R.sub.1 O(R.sub.2 O).sub.b (Z).sub.a I
wherein R 1 is a monovalent organic radical having from about 6 to about 30 carbon atoms; R 2 is a divalent alkylene radical having from 2 to 4 carbon atoms; Z is a saccharide residue having 5 or 6 carbon atoms; b is a number having a value from 0 to about 12; a is a number having a value from 1 to about 6. Preferred alkyl polyglycosides which can be used in the compositions according to the invention have the formula I wherein Z is a glucose residue and b is zero. Such alkyl polyglycosides are commercially available, for example, as APG®, GLUCOPON®, or PLANTAREN® surfactants from Henkel Corporation, Ambler, Pa. 19002. Examples of such surfactants include but are not limited to:
1. APG® 225 Surfactant--an alkyl polyglycoside in which the alkyl group contains 8 to 10 carbon atoms and having an average degree of polymerization of 1.7.
2. APG® 425 Surfactant--an alkyl polyglycoside in which the alkyl group contains 8 to 16 carbon atoms and having an average degree of polymerization of 1.5.
3. APG® 625 Surfactant--an alkyl polyglycoside in which the alkyl group contains 12 to 16 carbon atoms and having an average degree of polymerization of 1.6.
4. APG® 325 Surfactant--an alkyl polyglycoside in which the alkyl group contains 9 to 11 carbon atoms and having an average degree of polymerization of 1.5.
5. GLUCOPON® 600 Surfactant--an alkyl polyglycoside in which the alkyl group contains 12 to 16 carbon atoms and having an average degree of polymerization of 1.4.
6. PLANTAREN® 2000 Surfactant--a C 8-16 alkyl polyglycoside in which the alkyl group contains 8 to 16 carbon atoms and having an average degree of polymerization of 1.5.
7. PLANTAREN® 1300 Surfactant--a C 12-16 alkyl polyglycoside in which the alkyl group contains 12 to 16 carbon atoms and having an average degree of polymerization of 1.6.
8. GLUCOPON® 220 Surfactant--an alkyl polyglycoside in which the alkyl group contains 8 to 10 carbon atoms and having an average degree of polymerization of 1.5.
Other examples include alkyl polyglycoside surfactant compositions which are comprised of mixtures of compounds of formula I wherein Z represents a moiety derived from a reducing saccharide containing 5 or 6 carbon atoms; a is a number having a value from 1 to about 6; b is zero; and R 1 is an alkyl radical having from 8 to 20 carbon atoms. The compositions are characterized in that they have increased surfactant properties and an HLB in the range of about 10 to about 16 and a non-Flory distribution of glycosides, which is comprised of a mixture of an alkyl monoglycoside and a mixture of alkyl polyglycosides having varying degrees of polymerization of 2 and higher in progressively decreasing amounts, in which the amount by weight of polyglycoside having a degree of polymerization of 2, or mixtures thereof with the polyglycoside having a degree of polymerization of 3, predominate in relation to the amount of monoglycoside, said composition having an average degree of polymerization of about 1.8 to about 3. Such compositions, also known as peaked alkyl polyglycosides, can be prepared by separation of the monoglycoside from the original reaction mixture of alkyl monoglycoside and alkyl polyglycosides after removal of the alcohol. This separation may be carried out by molecular distillation and normally results in the removal of about 70-95% by weight of the alkyl monoglycosides. After removal of the alkyl monoglycosides, the relative distribution of the various components, mono- and poly-glycosides, in the resulting product changes and the concentration in the product of the polyglycosides relative to the monoglycoside increases as well as the concentration of individual polyglycosides to the total, i.e. DP2 and DP3 fractions in relation to the sum of all DP fractions. Such compositions are disclosed in U.S. Pat. No. 5,266,690, the entire contents of which are incorporated herein by reference.
EXAMPLE 1
About 150 grams of decyl alcohol ethoxylated with an average of 4 moles of ethylene oxide (0.45 OH equivalents) were mixed with 385 grams of toluene and 54 grams of 50% aq. NaOH (0.675 equivalents). The water was removed by azeotropic distillation and when a moisture level of less than 0.8% was reached, about 46 grams (0.51 equivalents) of epichlorohydrin were slowly added. This mixture was allowed to react at 100-110° C. for 24 hours. An aliquot of this mixture was removed and filtered to remove the NaCl and vacuum stripped to remove the toluene to give an amber, easily pourable liquid product that was dispersible in water. When about 1 gram of this liquid was shaken with 1 gram of decyl alcohol ethoxylated with an average of 4 moles of ethylene oxide in 50 grams of DI water, very little foam was observed. When 1 gram of decyl alcohol ethoxylated with an average of 4 moles of ethylene oxide in 50 grams of DI water was shaken, a very large amount of foam was observed.
EXAMPLE 2
About 51 grams of butanol ethoxylated with an average of 2 moles of ethylene oxide (0.32 OH equivalents) were mixed with 120 grams of toluene and 25 grams of 50% aq. NaOH (0.32 equivalents). The water was removed by azeotropic distillation and when a moisture level of less than 0.8% was reached, about 46 grams (0.24 equivalents) of epichlorohydrin were slowly added. This mixture was allowed to react at 100-110° C. for 24 hours. An aliquot of this mixture was removed and filtered to remove the NaCl and vacuum stripped to remove the toluene to give an amber, easily pourable liquid product that was insoluble in water. When about 1 gram of this liquid was shaken with 1 gram of decyl alcohol ethoxylated with an average of 4 moles of ethylene oxide in 50 grams of DI water, very little foam was observed.
EXAMPLE 3
About 200.0 gm (0.654 hydroxyl equivs.) of octyl alcohol ethoxylated with an average of 4 moles of ethylene oxide was mixed with 400 gm toluene and 78.4 gm (0.98 equivs.) of 50% NaOH. Water was removed by azeotropic distillation until the level was below 0.8%. The mixture was cooled to 80° C. and 67.2 gm (0.72 moles) of epichlorohydrin was added over 45 mins. The mixture was stirred for 24 hrs at 110° C. until the epoxy titration showed no epoxide left. The material was cooled, filtered and the toluene was removed by vacuum distillation leaving a dark brown low viscosity liquid.
EXAMPLE 4
A test mixture was prepared by mixing 51 parts (dry solids basis) of GLUCOPON® 220 Surfactant and 15 parts of a defoamer of Examples 1-3. The amount of foam produced by a 0.1% actives test mixture in water was compared with that of a 0.1% actives GLUCOPON® 220 Surfactant in water according to the method below. The data from this test is depicted graphically in FIG. 1.
The foam cell consists of a 2-liter jacketed graduate, peristaltic pump with variable voltage controller, and silicone and glass tubing. A test mixture is circulated at a constant temperature and flow rate, and falls from a constant height of 30 cm back into itself, creating foam. The tests are run under the following three sets of conditions: In the first test, a 0.1% active solution of the test surfactant in soft (10-15 ppm) water is circulated at 25° C. and the foam volume is read every 30 seconds. In the second test, a 0. 1% active solution in 1% NaOH is circulated at 25° C., and the foam volume is read every 30 seconds. In the third test, a 0.1% active solution in 1% NaOH is circulated. After 30 seconds, the foam volume is read and 1 ml of 1% TEA LAS solution is simultaneously added as a test-foamer. After another 30 seconds, the foam volume is read. About 30 seconds later, another 1 ml of 1% TEA LAS is added, and the foam volume is read 30 seconds after that. This cycle, in which every 30 seconds the test-foamer is added and 30 seconds later the foam volume read, is repeated until the foam volume exceeds 1,500 ml. The test is carried out both at 25° C. and at 49° C. This method gives us an indication of the antifoam capacity of the test surfactant. The relative defoaming characteristics of compounds according to the invention as measured by this method is shown in the FIGURE. | Defoamers are the products of the reaction of epichlorohydrin and compounds having the formula II
R.sub.3 (EO).sub.n (PO).sub.m OH (II)
wherein R 3 is an alkyl, alkenyl or arenyl group having from 4 to 22 carbon atoms; a substituted alkyl or alkenyl group having from 4 to 22 carbon atoms wherein; n is a number from 0 to 50 and m is a number from 0 to 10; wherein the mole ratio of epichlorohydrin to (II) is from about 0.60/1 to about 2/1 are extremely efficient defoamers for aqueous surfactant systems. The defoamers are added to a surfactant in an amount sufficient to reduce or eliminate foam and have the advantage of being totally dispersible in water, are readily biodegradable, contain no organic solvents and do not affect the detergency of surfactants with which they are used because they are nonionic surfactants in themselves. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority on the basis of Japanese patent application 2005-344637, filed Nov. 29, 2005. The disclosure of Japanese application 2005-344637 is hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to a ratchet type tensioner used for applying proper tension to a timing chain in a vehicle engine or the drive chain of a balancer or the like.
BACKGROUND OF THE INVENTION
In a typical timing transmission in a vehicle engine, an endless, flexible, traveling chain transmits rotation from a crankshaft sprocket to one or more camshaft sprockets. A ratchet tensioner is typically used to maintain proper tension in the slack side of the timing chain, that is, the side moving from away the crankshaft sprocket, in order to suppress vibration. The ratchet tensioner has a protruding plunger, and is mounted on the engine body in such a way that a front end of its plunger presses against the back of a pivoted tensioner lever, urging a shoe on the tensioner lever into sliding contact with the chain. A typical timing transmission using such a tensioner is described in U.S. Pat. No. 6,478,703.
In the case of a balancer, two balance shafts are provided with gears that mesh with each other, and a balancer chain is in mesh with a sprocket mounted on one balance shaft and a crankshaft sprocket. The balancer also includes a ratchet tensioner for maintaining proper tension in the balancer chain, as described in Japanese Laid-open Patent Publication No. 2004-308624.
An example of a conventional ratchet type tensioner is shown in FIG. 7 . In the tensioner 21 , a plunger 24 is slidable in a plunger-accommodating hole 23 in a tensioner body 22 , and protrudes forward from the front surface of the tensioner body. A compression spring 26 bears against the bottom of the plunger-accommodating hole in the tensioner body and extends through an opening at the rear of the plunger into a blind hole 25 inside the plunger 24 , its opposite end bearing against the closed end of the blind hole. The spring 26 continuously biases the plunger 24 in the protruding direction.
A longitudinal rack 27 is formed on the outer circumferential surface of the plunger 24 . The rack 27 comprises a series of rack teeth disposed at a uniform pitch over the entire length of the rack. The length of the rack is determined in accordance with the expected amount of loosening of the timing chain.
A pawl 29 is pivotably supported on the tensioner body 22 by a shaft 28 at a position adjacent the rack 27 . The pawl 29 is continuously biased clockwise by a spring 30 held in compression between the pawl and the bottom of a spring-receiving hole in the tensioner body. A first pawl tooth 29 a , and a second pawl tooth 29 b spaced rearward of the first pawl tooth 29 a , are engageable with the rack teeth 27 a . The pawl 29 and the rack teeth 27 a form a “backstop” mechanism 31 that blocks backward displacement of the plunger 24 .
The first pawl tooth 29 a , formed on the front side of the outer edge of the pawl 29 , has a triangular shape corresponding to the shape of rack teeth 27 a , and engages with a space between rack teeth substantially without a clearance. The second pawl tooth 29 b is smaller than the first pawl tooth 29 a . That is, its height, measured along a direction approximately perpendicular to the plunger axis, is lower than the height of pawl tooth 29 a . Tooth 29 b is formed at a location spaced rearward from tooth 29 b by at least three times the rack tooth pitch. When the first pawl tooth 29 a is engaged between two rack teeth 27 a substantially without any clearance, the second pawl tooth 29 b is out of contact with the rack teeth 27 a , and does not restrict movement of the plunger 24 . When the chain loosens by an amount permitting the plunger to protrude through a distance corresponding to half the width of one rack tooth 27 a , the plunger 24 begins to move forward and the first pawl tooth 29 a rides over the top of a rack tooth 27 a . The second pawl tooth 29 b then comes into contact with another rack tooth 27 a , causing the pawl to rotate clockwise, and causing the first pawl tooth 29 a to be engaged with another rack tooth 27 a . While the second pawl tooth 29 a is between two rack teeth, the plunger 24 can move slightly forward or backward in accordance with the looseness or tension in the chain, and the plunger 24 applies proper tension to the chain.
Both in the case of a timing chain and in the case of a chain for driving auxiliary equipment such as a balancer or the like, there are engines in which it would be desirable to have the backstop mechanism of a ratchet tensioner function only when the chain has become elongated after a lengthy period of operation. However, in a conventional ratchet tensioner, the length of the rack is such that it is opposite the ratchet pawl throughout the entire range of movement of the plunger. In such a tensioner, if the backstop mechanism is effective to prevent jumping of the chain on the sprocket teeth when the chain becomes elongated, it can exhibit insufficient backlash in the initial stages of its operation before the chain has become elongated. The tensioner cannot operate reliably in an engine that requires a tensioner having a backstop mechanism that functions in one region of plunger movement and does not function in another region of plunger movement.
Accordingly, an object of the invention is to solve the above-mentioned problems and to provide a ratchet tensioner that can be adapted to an engine of the kind that requires a tensioner having a backstop mechanism that functions only when the chain has become elongated, and does not function in the initial stages of operation of the chain.
SUMMARY OF THE INVENTION
In the improved ratchet tensioner according to the invention, as in the case of a conventional ratchet tensioner a plunger is slidable in a longitudinal direction in the plunger-accommodating hole of a tensioner body. The plunger has a front end that protrudes from the plunger-accommodating hole and a rear end within the plunger-accommodating hole. A plunger spring urges the plunger in the protruding direction, and a ratchet mechanism is provided for limiting movement of the plunger in a retracting direction. The ratched mechanism comprises a toothed rack having a set of rack teeth formed on the plunger and arranged in a longitudinal row, a pawl pivotably supported on the tensioner body for engagement with the rack teeth, and a spring biasing the pawl toward the rack teeth.
However the improved ratchet tensioner according to the invention differs from the conventional ratchet tensioner in that it has a recess formed in the plunger at a location between the toothed rack and the front end of the plunger. The recess is deeper than the tooth gap bottoms of the rack. Thus, the pawl can enter the recess without engaging the bottom wall of the recess, and permits the plunger to move freely in both its protruding and retracting directions through a limited range.
In a preferred embodiment, the plunger is provided with an additional tooth at a located between the recess and the front end of the plunger. The pawl is engageable with the additional tooth to hold the plunger in a fully retracted position, and prevents the plunger from jumping out of the plunger-accommodating hole prior to installation of the tensioner in an engine.
A protrusion engageable by the pawl is preferably formed on the tensoner body to limit pivoting movement of the pawl, thereby preventing the pawl from contacting the bottom wall of the recess in the plunger when the pawl enters the recess.
When the plunger is retracted to a position in which the pawl enters the recess of the plunger forward of the toothed rack, the ratchet mechanism does not function as a backstop mechanism. Thus, the punger is free to move forward and backward within a limited range. Excessive forward movement of the plunger is prevented, and proper tension can be maintained in the chain. However, as the plunger gradually moves forward with elongation of the chain over time, the pawl can engage the rack teeth, and the ratchet mechanism becomes operative to prevent the elongated chain from jumping the sprocket teeth. Thus, the ratchet tensioner of the invention can be adapted to an engine which requires a backstop mechanism having a non-operating range and an operating range, and in which the backstop mechanism becomes effective after the chain has become elongated over time.
When an additional tooth is provided forward of the recess in the plunger, the pawl can be used to hold the plunger in a fully retracted condition when the tensioner is shipped and transported, and when the tensioner is being installed in an engine either during initial assembly of the engine or in the process of repair of the engine.
A protrusion is provided to prevent excessive pivoting of the ratchet pawl, and thus prevents contact between the pawl and the bottom of the recess, especially when the bottom of the recess is flat. Furthermore, the protrusion prevents the pawl biasing spring from jumping out of its retaining hole as a result of excessive pivoting movement of the pawl.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a ratchet type tensioner according to the invention;
FIG. 2 is a cross-sectional view of the tensioner body;
FIG. 3 is a cross-sectional view of the plunger:
FIG. 4 is a cross-sectional view showing the tensioner in its initial state;
FIG. 5 is an explanatory cross-sectional view showing the tensioner in a state in which its ratchet does not perform a backstop function;
FIG. 6 is an explanatory cross-sectional view showing the tensioner in a state in which its ratchet performs a backstop function; and
FIG. 7 is a cross-sectional view of a conventional ratchet type tensioner.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The ratchet type tensioner 1 of the invention differs from the conventional ratchet type tensioner 21 shown in FIG. 7 in the shape of the rack formed on the outer circumferential surface of its plunger, and in that a protrusion 2 a is provided in the tensioner body 2 for engagement by the pawl.
As shown in FIG. 1 , the tensioner 1 includes a plunger 4 , which is fits slidably into a plunger-accommodating hole 3 ( FIG. 2 ) of tensioner body 2 so that the plunger 4 can be urged in the protruding direction by a compression spring 6 . A ratchet pawl 9 is pivotably supported on a pivot shaft 8 provided in a hole 8 a ( FIG. 2 ) in the tensioner body 2 , and biased by a spring 10 provided in hole 10 a ( FIG. 2 ) in the tensioner body. The pawl 9 has a first pawl tooth 9 a ( FIGS. 4 , 5 and 6 ), which is engageable with rack teeth 7 c of the rack 7 , as shown in FIG. 6 , in order to to block retraction of the plunger 4 . Thus, the pawl 9 and the rack teeth 7 c serve as a backstop mechanism 11 . A second pawl tooth 9 b is provided at a location rearward with respect to the pawl tooth 9 a.
As shown in FIG. 3 , a tooth 7 a is provided adjacent the front end of the rack for preventing jumping of the plunger out of the plunger-accommodating hole, and a recess 7 b is provided immediately rearward of tooth 7 a . The recess in the plunger preferably has a flat bottom. The flat bottom can be formed easily by milling or the like, and provides clearance for the pawl without impairing the strength of the plunger. The rack teeth 7 c , which cooperate with pawl 9 to perform the backstop function, are provided rearward of recess 7 b . The bottom of recess 7 b (which is a flat vertical surface in FIG. 3 ) is deeper than the tooth gap bottoms of tooth 7 a and rack teeth 7 c so that the first pawl tooth not come into contact with the bottom of recess 7 b.
As shown in FIGS. 2 and 4 , a protrusion 2 a is provided on the tensioner body 2 adjacent pawl 9 for the purpose of limiting the pivoting movement of the pawl under the biasing action of spring 10 , so that, when the ratchet 9 is pivoted by the biasing action of spring 10 , its tooth 9 a does not come into contact with the bottom of recess 7 b . By preventing excessive pivoting movement of the pawl, the protrusion 2 a also prevents the pawl biasing spring 10 from jumping out of its retaining hole 10 a ( FIG. 2 ).
As shown in FIG. 4 , when the tensioner is shipped and transported, and when it is being mounted on an engine either during assembly or during engine repair, the first pawl tooth 9 a of the ratchet 9 engages with tooth 7 a at the front of the rack 7 so that the plunger 4 is maintained in a retracted condition in the plunger accommodating hole 3 and does not jump out of the hole. Locking pins (not shown) may be removably inserted into holes formed in the pawl and tensioner body to prevent the pawl from pivoting until the ratchet is installed and in proper engagement with a tensioner lever or the like. Suitable locking means for the ratchet are well known and disclosed, for example, in U.S. Pat. No. 6,612,951, the disclosure of which is incorporated by reference.
When the tensioner 1 is mounted on an engine while in the state shown in FIG. 4 , the ratchet 9 may be pivoted slightly counterclockwise to disengage the first pawl tooth 9 a from tooth 7 a . The pawl 9 is then biased clockwise by spring 10 until it abuts protrusion 2 a on the tensioner body as shown in FIG. 1 . Then, the first pawl tooth 9 a opposite to the flat portion of recess 7 b does not engage any of the rack teeth on the plunger 4 , and the plunger can move freely in the protruding and retracting directions through a range 12 as shown in FIG. 5 . As mentioned above, since the pawl 9 abuts the protrusion 2 a , excessive pivoting movement of the pawl 9 is blocked, so that spring 10 cannot jump out of its hole 10 a ( FIG. 2 ).
When the first pawl tooth 9 a is located within recess 7 b but out of contact with the flat bottom of the recess, the plunger 4 is biased so as to protrude forward from the tensioner body 2 , and applies proper tension to the slack side of a chain (for example a timing chain, not shown) so that the chain cannot become excessively loose, vibrate, or disengage from its sprockets. Even if a large amount flutter is generated in the chain, the first pawl tooth 9 a does not engage rack teeth 7 c . Thus, the backstop mechanism 11 does not function while the plunger is operating within range 12 , and excessive tension is not applied to the chain.
When the chain becomes elongated after a period of operation in which the plunger is free to protrude and retract within range 12 , the plunger 4 gradually protrudes beyond range 12 , and the first pawl tooth 9 a engages a rack tooth 7 c as shown in FIG. 6 . As the plunger moves forward still farther in response to elongation of the chain the first pawl tooth 9 a passes over a rack tooth 7 c to engage with a next rack tooth, and so on. Retraction of the plunger is blocked by the backstop mechanism 11 when the plunger is within a range 13 shown in FIG. 6 . As a result, the plunger 4 applies proper tension to the chain as the chain gradually elongates, and thereby prevents jumping of the chain over the sprocket teeth.
In the operation of the tensioner described above and shown in FIGS. 1-6 , since the recess 7 b is not engaged by the pawl, and rack teeth 7 c are engageable by the pawl, the plunger can reciprocate freely in a region 12 during the initial stages of the useful life of a transmission chain, but the backstop mechanism becomes active when the chain becomes sufficiently elongated that the plunger extends into region 13 . Thus, excessive tensioning of the chain is prevented, but, as the chain becomes elongated, jumping of the sprocket teeth by the chain can be prevented. The tensioner, therefore, can be adapted to an engine which requires a backstop mechanism that has both a non-operating range, and an operating range in which it becomes effective as the chain becomes elongated.
The ratchet type tensioner of the invention can be used with a pivoted tensioner lever arranged so that the plunger of the tensioner presses against a back surface of the lever, thereby urging a shoe on the lever into sliding contact with a traveling chain. Alternatively, a member adapted for sliding contact with a travelling chain can be mounted directly on the front end of the plunger. | In a ratchet type chain tensioner, having a toothed rack on its plunger and a pawl cooperable with the rack, a recess is provided between the front end of the rack and the protruding end of the plunger. In the initial stages of operation of the tensioner, the pawl can enter the recess while permitting the plunger to protrude and retract freely within a limited range. Thereafter, when the chain controlled by the tensioner becomes elongated, the pawl cooperates with the rack to limit retraction of the plunger. | 5 |
This application is a continuation of U.S. application Ser. No. 11/117,638, filed Apr. 28, 2005, now U.S. Pat. No. 7,641,178 B2, which claims the benefit of provisional application Ser. No. 60/566,628, filed Apr. 29, 2004, the contents of each of which are hereby incorporated by reference herein.
FIELD OF INVENTION
A block for use in a system of interlocking modular blocks is described. In particular, blocks suitable for forming columns are described.
BACKGROUND OF THE INVENTION
Columnar structures used for decoration or as support for fence panels, gates or other such structures have required a considerable amount of skill and effort to erect. Conventional systems primarily include mortared masonry blocks. Columns or pillars also have been made from stone, but this requires skilled craftspeople to ensure proper structural completion.
Modular blocks have also been used to build columns or pillars. Such blocks can be installed without special skill. The advantages to such blocks are that they are a convenient size, a consistent size, and installation costs are less because of the lack of dependence on skilled labor. Blocks known in the art use construction adhesive to strengthen connection between layers and may be used with mortar to simulate the appearance of a more conventional block and mortar column.
An important feature of the building blocks is their appearance. The look of weathered natural stone is very appealing for columns and other similar structures. The art provides several methods to produce concrete blocks having an appearance that to varying degrees mimics the look of natural stone. According to one well-known method, blocks are individually formed in a mold and the surfaces are textured by removal of the mold. Additional machine texturing processes can then be applied. The look of smooth cut stone can also be very attractive for columns and other structures. The smooth texture provides a more straight edge, formal, geometric shape for the block and overall structural appearance.
A need in this art remains for blocks that can be used to construct mortarless, sturdy, reinforceable columns that have a desired appearance.
SUMMARY OF THE INVENTION
This invention is a system of blocks configured to be compatible with each other in the construction of a columnar structure. Each block has four faces that can either be textured in a manner resulting in an appearance like that of natural stone, or can be smooth to give a more formal appearance. All four faces of the block generally have the same dimensions. The faces of the block also may contain a slot to give the block a more aesthetic appearance by simulating the appearance of multiple blocks.
The blocks are provided with at least one interlocking element that permits a positive connection between courses of the blocks when the interlocking element is received in an overlying block. In one embodiment, the blocks interlock when there is a 90 degree rotation about a vertical axis of each block with each course. The blocks may be placed over a pipe or post-tensioning rod that is anchored into a foundation element in the ground. The core and the interlocking elements may be shaped to accommodate such a pipe and or post-tensioning rod. The blocks can be used to construct a column with a natural stone-like appearance or smooth appearance depending upon which type of block was used. Cores of stacked blocks form a passage through which vertical reinforcement can be used. This building block system is designed to be easy to install and structurally sound.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a building block according to this invention.
FIG. 2 is a top view of the building block of FIG. 1 .
FIG. 3 is a bottom view of the building block of FIG. 1 .
FIG. 4 is a side view of the building block of FIG. 1 .
FIG. 5 is a perspective view of another embodiment of a building block of this invention.
FIG. 6 is a side view of the block of FIG. 5 .
FIG. 7 is a top view of the block of FIG. 5 .
FIG. 8 is a perspective view of yet another embodiment of a building block of this invention.
FIG. 9 is a top view of the block of FIG. 8 .
FIG. 10 is a side view of the block of FIG. 8 .
FIG. 11 is a perspective view of still another embodiment of a building block of this invention.
FIG. 12 is a top view of the block of FIG. 11 .
FIG. 13 is a side view of the block of FIG. 11 .
FIGS. 14 and 15 are perspective views of a column of blocks according to this invention.
FIG. 16 is a side view of a fence having columns of blocks according to this invention.
FIGS. 17A and 17B are perspective views of two types of brackets used in conjunction with a block of this invention.
FIG. 18 is a perspective view of another type of bracket used in conjunction with a block of this invention.
FIG. 19A is a side view of a fence system of this invention and FIG. 19B is a top view of the fence system of FIG. 19A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In this application, “upper” and “lower” refer to the placement of blocks as a column is constructed. The lower or bottom surface of blocks is the surface that faces the ground in a column. The first course of the column is formed by placing one block so that its lower surface is face-down. Subsequent courses are formed by stacking blocks so that an interlocking element or projection from one block fits into an indentation or void of an overlying block. “Top” and “bottom” surfaces are defined as those most conventionally used for these blocks, however, the blocks can be used with tops and bottom reversed.
The blocks of this invention may be made of a rugged, weather resistant material, such as concrete, especially if the columnar structure is constructed outdoors. Other suitable materials include plastic, reinforced fibers, wood, metal and stone. The surface of the blocks may be smooth or may have a roughened appearance, such as that of natural stone. The blocks typically are formed in a mold and various textures can be formed on the surface, as is known in the art.
Each block has four faces which can either be textured in a manner resulting in an appearance like that of natural stone, or can be smooth to give a more formal appearance. All four faces of the block may have the same dimensions. One or more faces of the block optionally may contain one or more slots that will be visible in the columnar structure to give a column of blocks a more aesthetic appearance.
In typical use, the interlocking element extends above the top surface of the block and projects into an indentation in an overlying block. In a preferred embodiment, the indentation is the core; that is, the core extends through the thickness of the block. In one preferred embodiment, two interlocking elements extend above the top surface of the block into the core of the overlying block, thus producing positive interconnection between facing surfaces. In a preferred embodiment, each successive block is rotated by 90 degrees about its vertical axis thus causing the interlocking elements to project into the core of the block above it. The interlocking elements hold the blocks in place and eliminate the need for mortar when constructing the column.
Rotation of each block about its vertical axis also varies the location of the slot, if present, resulting in a more eye-pleasing pattern for the column. Rotation of the blocks as a column is built also serves to produce a straight column. Because block molding processes may result in uneven blocks, stacking the blocks all in the same orientation may cause a column to tilt or lean. This problem is usually solved by shimming the blocks to make them level. With the block system of this invention, shimming is unnecessary.
The blocks can be used to form various types of columns, such as free standing, decorative columns, gate columns, or columns for use with fence panels.
Turning now to the drawings, the blocks of this invention are described. FIGS. 1 to 4 show block 100 , comprising top or upper surface 112 , bottom or lower surface 113 , first and second opposed sides 114 and 116 , and third and fourth opposed sides 115 and 117 . Top surface 112 is spaced apart from opposing lower surface 113 , thereby defining a block thickness. Opposed sides 114 / 116 and 115 / 117 have substantially the same surface area. The top and bottom surfaces 112 , 113 together with the first through fourth sides 114 , 115 , 116 and 117 form block body 100 .
The surfaces of the block meet to form edges and corners. The corners may be beveled, chamfered or rounded to give a more weathered natural stone-like appearance.
Block 100 has optional slot 118 on each side. The slot is a trough on the side and top surfaces, extending from the bottom surface to the core. The slot results in a desirable appearance of stacked blocks, aids in positioning the block when forming a column, and allows the top surface to receive a bracket so that the block can be attached to a fence segment, as described further below.
Block 100 is provided with core 120 located in the center of the block. Core 120 extends the thickness of the block and is desirable because a core results in reduced weight for the block. The core is also useful when forming a column because vertical reinforcement can be inserted through the vertically aligned cores to lend stability to the columnar structure. For example, concrete grout and rebar, steel pipe, or post-tension rods can be used to fill the core and strengthen the structure.
Core 120 is generally rectilinear, having walls generally parallel to the side surfaces. On opposing inside corners of core 120 are located two interlocking elements 122 . These elements extend the thickness of the block, and project above the top surface of the block. They are essentially co-planar or parallel with the bottom surface of the block, that is, the bottom surface of the block is essentially co-planar or contiguous with the bottom surfaces of these elements.
Although neither the interlocking elements nor the core need extend the thickness of the block, typically it is simpler to manufacture the blocks this way. In any event, the interlocking elements extend a distance above the top surface of the block. This distance is sufficient to provide adequate interlocking between blocks when a second block is stacked on a first block.
Block 100 has interlocking elements that are mirror images of each other on a diagonal plane of symmetry through the block. These interlocking elements are positioned to permit the alignment of blocks directly over one another when rotated 90 degrees about the vertical axis of the block. The interlocking elements also help to lock blocks into place, thus adding stability to a column of the blocks. Most preferably, the interlocking elements are shaped so that a pipe or post-tensioning rod can be installed vertically in the center of the block and through the center of the column. That is, as shown in the figures, the portion of the projection facing the center of the core is curvilinear.
It is to be emphasized that it is generally preferred that the blocks be used in the orientation described above, but there is nothing precluding the use of the blocks wherein the projections extend into the core of an underlying block.
FIGS. 5 to 7 illustrate another block 200 of this invention. Block 200 is substantially the same as block 100 , except that slots 218 are located at a midpoint on two opposing sides of the block. The slots extend from the bottom of the block to the core.
Block 200 comprises top or upper surface 212 , bottom or lower surface 213 , first and second opposed sides 214 and 216 , and third and fourth opposed sides 215 and 217 . Top surface 212 is spaced apart from opposing lower surface 213 , thereby defining a block thickness. Opposed sides 214 and 216 and 215 and 217 have substantially the same surface area. The top and bottom surfaces together with the first, second, third, and fourth sides form a block body.
Core 220 extends the thickness of the block. Core 220 is generally rectilinear, having walls generally parallel to the side surfaces. On opposing inside corners of core 220 are located two interlocking elements or projections 222 , which project above the top of the block and are parallel with the bottom of the block. The remaining descriptions of the various features of block 100 apply equally to corresponding features of block 200 .
FIGS. 8 to 10 show another embodiment of a block, similar to block 200 , but having recessed areas opposed to each other on the top surface of the block. The recesses accept variously-shaped brackets and permit the blocks to stack evenly, as will be described further below.
Block 300 comprises top or upper surface 312 , bottom or lower surface 313 , first and second opposed sides 314 and 316 , and third and fourth opposed sides 315 and 317 . Top surface 312 is spaced apart from opposing lower surface 313 , thereby defining a block thickness. Opposed sides 314 and 316 and 315 and 317 have substantially the same surface area. The top and bottom together with the first, second, third, and fourth sides form a block body. The top edges 334 and 335 of the block are beveled to produce a desired appearance. In addition, the sides meet at beveled corners 333 .
Slots 318 are located at a midpoint on two opposing sides of the block, and the slots open onto the top and bottom surfaces of the block. Block 300 has recessed areas 323 on the top surface of the block. Whereas in blocks 100 and 200 , the slots ( 118 and 218 , respectively) continue on the top surface of the block, in block 300 , instead of the slots, there are recessed areas 323 . Recessed areas 323 extend from the sides of the block and open onto the core.
Core 320 extends the thickness of the block. Core 320 is generally rectilinear, having walls generally parallel to the side surfaces. On opposing inside corners of core 320 are located two projections or interlocking elements 322 , which project above the top surface of the block. Use of block 300 in the construction of a fence will be described further below. The remaining descriptions of the various features of block 100 apply equally to corresponding features of block 300 .
FIGS. 11 to 13 illustrate another embodiment of the block of this invention, in which there are four recesses in the top of the block. These permit the use of a bracket during construction of a fence, as will be described later herein; the bracket can be used on any side of the block.
Block 400 comprises top or upper surface 412 , bottom or lower surface 413 , first and second opposed sides 414 and 416 , and third and fourth opposed sides 415 and 417 . Top surface 412 is spaced apart from opposing lower surface 413 , thereby defining a block thickness. Opposed sides 414 to 417 have substantially the same surface area. Top edges 434 and 435 of the block are beveled and the sides meet at beveled corners 433 .
Slots 418 are located at a midpoint on two opposing sides of the blocks and extend from bottom surface 413 to (and through) beveled edge 434 . Recessed areas 423 extend from the core toward the beveled top edges but not to the sides of the block. In this way, each side of the block has a desirable appearance for use in any orientation in a column. On the opposite side of the core from each recessed area is projection or interlocking element 422 .
Core 420 extends the thickness of the block. Core 420 is generally rectilinear, having walls generally parallel to the side surfaces. On opposing inside corners of core 420 are located two interlocking elements or projections 422 , which project above the top surface of the block.
As shown in FIGS. 11 and 12 , region 425 on the top of the block is adjacent to both the side surface (i.e., 414 or 416 ) and the recessed area 423 . Region 425 is useful in preventing the flow of caulk or construction adhesive to the outside of the block when used in recessed area 423 . When using a bracket with block 400 , it may be desirable to remove region 425 to reduce its height to that of recessed area 423 , thus allowing a bracket to fit across the recessed area and allowing stacked blocks to lie flat, as will be described further below. For example, when a block comprises concrete, the installer chips this portion away.
The blocks of this invention can be manufactured to any desired dimension; typically, the thickness is about half the width of the block. The width of the block (i.e., the distance between two opposing sides, as measured at a midpoint) typically varies from about 12 inches (30.4 cm) to about 18 inches (45.7 cm). A convenient thickness (i.e., in terms of utility and appearance) is from about 6 inches to about 8 inches (about 15.2 to 20.3 cm). Block dimensions are selected not only to produce a pleasing shape for the desired column, but also to permit ease of handling and installation. Typically, blocks of one thickness are used to construct a column.
The presence of the core serves not only to provide a space for interlocking elements to fit when the blocks are stacked, but it also reduces the weight of the block. It may be desirable to further reduce the weight, to make the blocks easier to handle. This can be done by adding cores in the block. For example, one or more cores can be formed near the corners of the block when the block is molded.
FIG. 14 shows column 500 formed of blocks 100 . A first block is set upon base 510 . This base typically comprises concrete and may range in diameter from about 18 to 24 inches (45.7 to 61 cm). The particular foundation element (e.g., the base) is determined based on the load, the soil condition, and other factors by a qualified engineer. Of course, larger diameters may be used to support greater horizontal and vertical loads. The base may be formed by using a tubular form or mold or by other methods as are known in the art.
Base 510 is set into the ground to at least 24 inches (61 cm) or to frost depth as determined by local building codes. The first block is set down and each subsequent block is rotated 90 degrees about its vertical axis and stacked upon a lower block. Thus, the interlocking projections on the upper surface of a block below fit into the core of a block above. The presence of slots 118 is decorative, resulting in a pleasing appearance.
Column 500 is shown with a vertically aligned pipe as an optional interior reinforcement. As a practical matter, the pipe is placed into the foundation element (in the ground), and then a form is built around it for base 510 . The blocks are stacked over pipe 520 . Pipe 520 is preferably made of galvanized steel and has an outer diameter of about 2.375 inches (about 6 cm).
FIG. 15 shows column 500 (in phantom) with a different reinforcement from that of FIG. 14 . This reinforcement is a post-tensioning system comprising post-tensioning rod 521 , which is tightened after it is installed. There is one mating pair of connectors at the base and another pair of mating connectors at the top of the column. The first mating pair comprises ring 522 and hook 524 . Ring 522 is formed into base 511 , which typically is formed in place out of concrete. The blocks are stacked, and then a tension rod having hook 524 on the end is threaded through the block cores and hooked onto ring 522 . The second mating pair of connectors comprises compression plate 526 and washer/nut 527 / 529 . The tension rod fits through a hole in the plate. Compression plate 526 is placed onto the tension rod at the top of the block column along with nut 529 and washer 527 . Nut 529 is turned to produce a specified tension on rod 521 .
FIG. 16 illustrates a side view of fence 990 wherein fence posts 900 are columns comprising the blocks of this invention. Each column 900 is formed on base 910 . Preferably, there is reinforcement, such as the pipe of FIG. 14 or the tension rod of FIG. 15 , extending through the cores of adjacent blocks in the column to provide additional strength to the column. Cap layer 930 closes the top of each column. The columns are attached to fence panels 940 . The fence panels may comprise wood, vinyl, steel, wrought iron, aluminum, plastic, fiberglass, precast concrete, glass, plexiglass, and the like. The panels may be in the form of a picket fence or railing, or they may be solid.
Various ways may be used to attach fence panels to the columns, as illustrated in FIGS. 17 and 18 . FIG. 17A shows a single block 300 , with pipe 520 centered in core 320 and U-shaped bracket 530 that attaches to a fence panel. U-shaped bracket 530 comprises base portion 532 , which fits over recessed area 323 , arm 534 which lies inside the core of the block, and arm 536 , to which are attached extensions 538 . Though two extensions are shown, one extension would suffice, and such a bracket. Nails or screws are used through holes 539 to attach bracket 530 to a fence panel.
Bracket 540 is shown in FIG. 17B . For simplicity, no block is shown. This bracket has base portion 542 attached to arm 544 , which is attached to ring clamp 545 . The ring clamp is affixed around pipe 520 that runs through the cores of the blocks in the column. Arm 546 extends from base portion 542 and has extensions 548 with holes 549 through which nails or screws are placed to attach the bracket to a fence panel.
FIG. 18 shows another kind of bracket 550 that has curved segment 554 that fits around pipe 520 (shown in phantom). Straight portion 552 fits through slot 118 through the top or upper surface 112 of block 100 , shown partially in phantom, and terminates at perpendicular segment 556 , which fits into holder 945 mounted on fence panel 940 . Bracket 550 is thus sandwiched between courses of blocks. This bracket also could be used with block 300 , fitting anywhere in the recessed region 323 , and could be used with block 400 if a portion of the region 425 were removed. However, the advantage to this bracket 550 is that it fits within a slot on top surface of the block (such as slot 118 in the top surface 112 of block 100 or slot 218 in the top surface 212 of block 200 ). No additional recessed area is needed to stack blocks evenly in the presence of a bracket. The bracket preferably is made of galvanized steel and has a length sufficient to span the distance from a pipe at the center of the block to a fence panel.
FIG. 19A illustrates a side view of a portion of fence 992 wherein columns 900 comprise blocks 300 and form fence posts for the fence. Each column 900 is formed on base 910 (shown in phantom). Pipe 520 (also shown in phantom) extends through the cores of adjacent blocks in each column and is embedded in base 910 . Brackets 530 join fence segments 942 to the columns. Each column is capped with capping block 930 . FIG. 19B illustrates a top view of the fence, showing placement of the block without the cap layer in place. This view illustrates how the fence segments are positioned relative to the columns.
Blocks of this invention also may be used with other blocks having interlocking elements, such as those described in commonly assigned, co-pending U.S. application Ser. No. 11/117,640, filed on Apr. 28, 2005, herewith entitled “Columnar Block Fence System,” which claims the benefit of commonly assigned, co-pending U.S. Provisional application Ser. No. 60/566,590, filed Apr. 29, 2004 entitled “Columnar Block Fence System,” both of which applications are hereby incorporated herein by reference.
Although particular embodiments have been disclosed herein in detail, this has been done for purposes of illustration only, and is not intended to be limiting with respect to the scope of the claims. In particular, it is contemplated that various substitutions, alterations and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. For instance, the choice of materials or variations in the shape or angles at which some of the surfaces intersect are believed to be a matter of routine for a person of ordinary skill in the art with knowledge of the embodiments disclosed herein. | A system of blocks is configured to be compatible with each other in the construction of a columnar structure. Each block has four faces and all four faces may generally have the same dimensions. The width of the blocks may generally be about twice their height. The faces of the block also may contain a slot to add an aesthetic appearance to the column. The blocks have certain constructions features that mate with specially constructed brackets in attaching a fence panel to the completed column.
The blocks have interlocking elements or projections that permit positive connection between courses of blocks. Projections of one block extend into the core another block. Adjacent blocks can be rotated 90 degrees relative to each other about a vertical axis of each block with each course. The blocks can be used to construct a column that is easy to install and structurally sound. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally concerns a new method of engineering a kidney in vitro.
The present invention particularly concerns a new method and procedure for propagating cloned kidney members from embryonic ureteric bud tips grown in vitro under specific culture conditions.
2. Description of Related Art
Branching tubulogenesis is an essential mechanism by which epithelial tissues such as kidney, salivary gland and prostate develop (Proc. Natl. Acad. Sci. USA, 96, 7330–7335, 1999 incorporated herein by reference). Largely based on the classical studies of Brobstein and coworkers, direct interactions between mesenchymal and epithelial components of embryonic tissue have been thought to be crucial for branching morphogenesis in most epithelial tissues. During kidney development, for example, direct cell-cell interactions between the metanephric mesenchyme and the epithelial component, the ureteric bud (UB), are believed to be essential for branching morphogenesis of the latter. This view is based on the fact that it had not been possible, in many previous studies, to observe proliferation and branching of the UB in the absence of direct contact with the metanephric mesenchyme or another inducing tissue, suggesting that the developmental program necessary for branching depended upon direct contact between surface proteins of the UB with surface proteins of the metanephric mesenchyme. Further, no known soluble factor or set of factors had been able to induce UB branching morphogenesis in vitro.
This view has gained additional support from knockout experiments in which absent expression of a variety of individual soluble growth factors held to be important in kidney development, based upon previous organ culture experiments, fail to show defective branching morphogenesis of the UB. Nevertheless, recent studies have also shown that glial cell line derived neurotrophic factor (GDNF) is necessary for early UB outgrowth, but on its own, it fails to promote proliferation and branching morphogenesis of isolated UB in vitro. These results left open the possibility that some unknown soluble factor, or combination of factors, derived form the metanephric mesenchyme, might be sufficient to induce epithelial branching morphogenesis.
A wide array of renal and urological abnormalities are likely due to defective tubulogenesis and branching morphogenesis of the developing collecting system
It is now clear that a variety of defects in the kidney and urinary collecting system are the result of abnormal development of these structures in the fetus. The spectrum of disease is huge, as is their potential morbidity. The molecular basis for these diseases is poorly understood; however, it appears, in many instances, that the problem lies in defective morphogenesis of the ureteric bud. The urinary collecting system (from the trigone of the bladder including ureteral orifices, ureters, renal pelvis, and collecting tubules) arises from the UB. Thus, developmental abnormalities of the UB and its derivatives would be expected to give rise to a variety of “urological” as well as “nephrological” clinical syndromes. Developmental anomalies extrinsic to the kidney, but in principle attributable to defects in UB morphogenesis, include vesicoureteral reflux (VUR), ureteropelvic junction obstruction (UPJO), ectopic and duplicated ureters. Since normal kidney development depends critically upon mutual inductive interactions between the UB and the metanephric mesenchyme (MM), inefficient or defective branching morphogenesis of the UB would be expected to result in various aplastic, hypoplastic, and perhaps dysplastic diseases. Extrinsic collecting system abnormalities would then be expected to, coexist with various hypoplastic diseases of the kidney. In fact, up to ⅓ of end stage renal disease in children is due to developmental problems, the majority of which may be categorized as ureteral with or with out dysplasia or hypoplasia of one or both kidneys. In addition, perhaps 5–10% of all adults has some occult developmental anomaly.
Recent advances in the molecular biology of kidney development demonstrate that specific molecular defects can explain a variety of clinical syndromes. VUR, UPJO, and various dysplastic, and hypoplastic kidney disorders have been known to co-exist and to be expressed in various human lineages with a variable penetrance, the so-called CAKUT syndrome. In addition, several targeted gene-deletion experiments have resulted in phenotypes that may be best characterized as resulting form defective UB morphogenesis (directly or indirectly). These range from the renal aplasia associated with complete UB failure associated with deletions of WT-1 and RTK c-ret molecules to more subtle effects resulting in hypoplasia or oligonephronia such as seen with certain integrin knockouts. Defective collecting system development may play a role in the most common congenital cystic disease, ADPKD. The inventors have shown that expression of PKD-1 correlates spatiotemporally with branching morphogenesis of the UB. Findings such as this have led to the hypothesis that ADPKD and other cystic diseases of the kidney result form defects in the developmental program necessary for proper tubulogenesis.
Aside from “congenital” disease per se, defective collecting system development may underlie predisposition to disease much later in life. It has been argued that low nephron number is crucial to the development of hypertension and chronic renal failure in adults. This may well be the result of defective branching morphogenesis during development of the urinary collecting system, because the degree of ureteric bud branching during collecting system development determines the number of nephrons in the adult kidney. Hence, aggregate nephron number is a function of factors regulating ureteric bud branching during urinary tract development. If one assumes a 1% decrement in efficiency of branching morphogenesis (99% efficient at all steps), this results in less than half the normal number of nephrons after the roughly 20 generations of branching which occur during human nephrogenesis.
In summary, a broad spectrum of disorders ranging from urological abnormalities, hypoplasia, dysplasia, and cystic diseases, and possibly even certain forms of “essential” hypertension, may be viewed as developmental diseases of ureteric bud and its derivatives. Recent work indicates that a molecular basis exists for these disorders and that much human morbidity and mortality may be attributable to varying degrees of failure in the process of ureteric bud branching morphogenesis.
The cellular and molecular basis of development of the urinary collecting system, particularly tubulogenesis and branching morphogenesis, are not well understood
In the mouse, inductive interactions between the MM and the UB that are necessary for formation of the metanephric kidney take place around embryonic day 11; in the rat, this occurs around day 13. Through in vitro organ and cell culture studies, as well as knockouts, both soluble factor influence and cell—cell contact have been implicated, although the exact nature of the inducing signals is a topic of intense investigation and debate. Subsequent to these interactions, the metanephric mesenchyme undergoes a “mesenchymal to epithelial transition,” during which it acquires epithelial markers such as cytokeratins. As development progresses, the recently epithelialized mesenchyme forms early nephronal structures, which ultimately develop into the proximal through distal tubule. All this appears to be guided by interactions with the ureteric bud as it, through a process of branching morphogenesis, develops into the collecting system. Thus, while the mesenchyme is differentiating, the ureteric bud is invading it and undergoing iterations of symmetric and asymmetric dichotomous branching. About 20 generations of such branching events result in the roughly 1 million collecting ducts that form the renal portion of the urinary collecting system.
This general process is not unique to the kidney. Branching tubulogenesis (ductogenesis) is an essential mechanism by which most, if not all, epithelial tissues form in the embryo. Largely due to the classical studies using organ culture, direct interactions between mesenchymal and epithelial components of embryonic tissue have been thought to be crucial for branching morphogenesis in kidney and urinary tract. This view is based on the fact that it had not been possible, in many previous studies, to observe proliferation and branching of the UB in the absence of direct contact with the metanephric mesenchyme or another inducing tissue, suggesting that the developmental program necessary for branching depended upon direct contact between surface proteins of the UB with surface proteins of the metanephric mesenchyme. Furthermore, no known soluble factor or set of factors had been able to induce UB branching morphogenesis in vitro. This view has gained additional support from knockout experiments in which absent expression of a variety of individual soluble growth factors held to be important in kidney development (based upon previous organ culture experiments) fail to show defective branching morphogenesis of the UB. Nevertheless, recent studies have demonstrated that glial cell line derived neurotrophic factor (GDNF) is necessary for early UB outgrowth, but as the inventors have shown, on its own, it fails to promote proliferation and branching morphogenesis of isolated UB in vitro ( FIG. 6 ). [Proc. Natl. Acad. Sci., 96, 7330–7335, 1999 incorporated herein by reference].
The primary focus of this invention is to present a novel method and procedure for propagation of cloned kidney members from embryonic ureteric bud which also has applicability to other epithelial-derived tissues. This method differs in concept and substance from U.S. Pat. No. 6,060,270 (May 9, 2000) issued to Humes. In contrast to the Humes patent, this method employs the intrinsic ability of the embryonic epithelial tissue to branch in order to generate an indefinite number of organs from a single embryonic ureteric bud. Thus, in principle, after six generations of branching, a single ureteric bud can give rise to 256 (2 8 ) kidneys or even more, depending upon the number of generations the ureteric bud is allowed to branch in culture.
SUMMARY OF THE INVENTION
The primary object of this invention is to provide functioning replacement organs or functional fragments thereof that are suitable for transplanting into recipients suffering from a variety of life-threatening diseases or developmental anomalies.
Another object in accordance with the present invention is to generate functional mammalian epithelium-derived organs, or active fragments thereof from embryonic explants, tissues or cells utilizing in vitro culture techniques.
Another object of this invention is to define soluble inducing factors effective in transforming embryonic epithelial cells or tissues into regenerating functional organs, glands and the like.
A further, most preferred object is to provide a bank of embryonic organs and tissues capable of replacing diseased, or otherwise incapacitated vital organs and tissues, minimizing the need for matching donors and/or immunosuppressive drugs.
In accordance with these objects, this invention contemplates a method for constructing a functional mammalian tubulogenic organ or fragment thereof in vitro. The method involves culturing and propagating embryonic explants, tissues or cells by isolating said explants, tissues or cells and growing them in culture with specific soluble and insoluble inducers for sufficient periods of time to allow the cultured specimens to form multiple branches. The tips of these branches are then dissected out and recultured in the presence of serum, growth factor mix, mixture of conditioned and nutrient-rich medium for several generations to form 3-dimensional tubulogenic structures with multiple growing tips. This process can proceed ad infinitum under proper culture conditions having effective inducer substances.
The contemplated method further involves culturing and propagating embryonic mesenchymal tissues capable of inducing limited differentiation and directional growth to form functional organs or tissues. The mesenchymal or other inducing tissue fragments are dissected out at the time of induction, and cultured in the presence of serum, growth factor mix, and a mixture of appropriate conditioned medium and nutrient-rich medium. After several passages in primary culture, growing inductive tissue may be partitioned into multiple fragments. Each fragment can then grown separately in culture. Vasculogenesis within each fragment is induced by substrate deprivation and/or the addition of specific soluble factors.
Finally, a grown, vascularized tissue fragment is combined in coculture with a cultured tubulogenic fragment described hereinabove, in a matrix in which in vitro angiogenesis has begun. The two tissue fragments are grown in nutrient-rich medium conditions to enable continued vasculogenesis. Alternatively, the “cloned” kidney can be implanted for in vivo vascularization.
A more specific and preferred embodiment of this invention is a method for generating a functional mammalian kidney in vitro by culturing and propagating ureteric bud tissue. This method comprises isolating embryonic kidney rudiments by dissection, isolating ureteric bud tissue fragments from mesenchyme by incubating the kidney rudiments with a proteolytic enzyme in the presence of DNAase and/or by mechanical separation. The isolated ureteric bud fragments are suspended in a gel matrix and the gel/fragment composition is placed on porous polycarbonate membrane inserts in wells of tissue culture plates. Growth factors are added to the culture wells, and the gel composition comprising the bud fragments is maintained at the interface of air and medium until the fragments form multiple tubular branches inside the gel matrix. Individual distal branch tips formed during culture are dissected out and recultured in the presence of serum, growth factor mix, mixture of mesenchymal and ureteric bud cell conditioned medium and nutrient-rich medium for several generations.
The mechanical separation of tissue fragments can be accomplished by manual dissection or laser separation and capture. The growth factor mix includes glial cell line-derived neurotrophic factor or functional equivalent thereof. The added conditioned medium contains a heretofore-unidentified growth promoting constituent and/or inducer of differentiation. The extracellular matrix gel comprises a mixture of type I collagen and Matrigel or a comparable support matrix.
An equally preferred embodiment in accordance with this invention is method for simultaneous in vitro culturing and propagation of metanephric mesenchyme. This method comprises dissecting out fetal kidney mesenchyme tissue at the time of induction, culturing fragments of the mesenchymal tissue in the presence of serum, growth factor mix, mixture of mesenchymal and bud cell conditioned medium and nutrient-rich medium, and partitioning the cultured mesenchyme into multiple pieces. Each piece is grown separately in culture for several generations and grown mesenchyme is then subjected to substrate deprivation and/or additional growth factors in order to induce vasculogenesis.
A most preferred embodiment in accordance with this invention is a method for in vitro engineering and constructing a functioning mammalian kidney by culturing and propagating an isolated ureteric bud, permitting the cultured bud to form multiple branches, dissecting out the individual branch tips, and reculturing in the presence of serum, growth factor mix, mixture of mesenchymal and bud cell conditioned medium and nutrient-rich medium for several generations. The method also comprises simultaneously culturing and propagating isolated embryonic or fetal metanephric mesenchyme by dissecting out fetal mesenchyme at the time of induction, culturing mesenchymal tissue in the presence of serum, growth factor mix, mixture of mesenchymal and bud cell conditioned medium and nutrient-rich medium, potentially partitioning the mesenchyme into multiple pieces with the option of growing each piece separately, and inducing vasculogenesis by subjecting grown mesenchyme to substrate deprivation. The most preferred method then provides for recombining each vascularized mesenchyme piece with each cultured bud in a matrix in which in vitro angiogenesis has begun, and growing in richest medium conditions to ensure continued vasculogenesis.
Thus, in the most preferred embodiment, is a functional mammalian kidney constructed from isolated embryonic or fetal kidney tissue or cells cultured in rich medium that has present a mixture of growth factors and inducer substances, and comprises recombination of an isolated ureteric bud propagated in culture to produce a functioning nephron, and metanephric mesenchyme propagated from cultured embryonic mesenchymal tissue fragments or cells. Said mesenchyme has the capability of inducing differentiation and providing directional guidance to the branching tubulogenic bud.
Still further embodiments and advantages of the invention will become apparent to those skilled in the art upon reading the entire disclosure contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : A schematic representation of the methodology and salient points of this invention. A schematic diagram showing a novel culture method for inducing in vitro branching morphogenesis of an isolated ureteric bud (UB), simultaneous culture of mesenchymal tissue and recombination and coculturing of the two cultured tissue fragments. The mesenchymal tissue added to the bud culture induces the bud to directionally extend branching tubules and further differentiate and incorporate to form a functioning nephron, capable of absorbing, filtering, collecting and secreting body fluids. Schematically depicted is a ureteric bud fragment in culture 2 , being induced by a stimulant(s) to produce a pluripotent fragment 3 , that is capable of branching morphogenesis to form a branched three-dimensional structure 4 . It can be see that an excised growing tip 2 can be further cultured in the presence of an inducer(s) 1 to again form an activated fragment 3 , that will continue its tubulogenic morphogenesis. Simultaneously, an isolated fragment of mesenchymal tissue 5 is grown in culture to produce multiple pieces of mesenchymal tissue. One such piece 6 is grown and is then placed in coculture with an actively branching bud fragment 7 . The bud fragment, under influence of the mesenchymal induction continues to branch in a now directed fashion and to further differentiate to form maturing effluent collecting tubules, enlarging as the branching progresses to accommodate increased effluent and incorporating into new nephrons. Eventually an embryonic kidney, or a functionally equivalent fragment thereof, is formed 8 .
FIG. 2 : A novel culture system for in vitro branching morphogenesis of the ureteric bud (UB) (Proc. Natl. Acad. Sci., 96, 7330–7335, 1999 incorporated herein by reference—please refer to this paper for color reproductions). UBs free from mesenchyme were micro-dissected from E-13 rat kidney rudiments and placed in an ECM gel suspension composed of type I collagen and growth factor-reduced Matrigel®, and cultured in BSN cell-conditioned medium (BSN-CM) supplemented with 10% FCS and growth factors. Details are given elsewhere in the text. The cultured UB was monitored daily by microscopy. Shown in the figure is transwell insert ( 1 ), ECM gel ( 2 ), isolated UB ( 3 ), polycarbonate filter ( 4 ), and BSN-CM plus growth factor(s) ( 5 ).
FIG. 3 : The UB undergoes branching morphogenesis in vitro and develops three-dimensional tubular structures in the absence of mesenchyme (Proc. Natl. Acad. Sci., 96, 7330–7335, 1999 incorporated herein by reference-please refer to this paper for color reproductions). E-13 rat UB was isolated and cultured as described herein below. After culture, UBs were fixed at different time points and processed for DB lectin staining. 3-D reconstructions of confocal images are shown: a) A freshly isolated UB from an E-13 rat embryonic kidney with a single branched tubular structure; b) The very same UB shown in a) after being cultured for 3 days. The tissue has proliferated and small protrusions have formed; c) Again, the same UB as shown in a) cultured for 6 days. More protrusions have formed, and the protrusions have started to elongate and branch dichotomously; d) the same UB as shown in a) cultured for 12 days. The protrusions have undergone further elongation and repeated dichotomous branching to form a structure resembling the developing collecting system of a kidney. The white arrows indicate branch points. At higher power, the structures formed in this in vitro culture system exhibited lumens. Phase microscopic examination and staining for markers revealed no evidence for contamination by other tissue or cells.
FIG. 4 : BSN-CM and at least one soluble growth factor are required for branching morphogenesis of the isolated UB (Proc. Natl. Acad. Sci., 96, 7330–7335, 1999 incorporated herein by reference-please refer to this paper for color reproductions). A: The UB cultured in the absence of BSN-CM and growth factors; B: The UB cultured with the mixture of growth factors (including EGF, IGF, HGF, FGF-2, and GDNF) but no BSN-CM; C: The UB cultured in the presence of BSN-CM alone; D: The UB cultured in the presence of both BSN-CM and the mixture of growth factors. All cultures were carried out for about one week and then processed for DB lectin staining. Shown is the three-dimensional reconstruction of confocal images. The isolated UB exhibits branching morphogenesis only in the presence of both BSN-CM and the mixture of growth factors.
FIG. 5 : BSN-CM contains unique soluble factor(s) for branching morphogenesis of the isolated UB (Proc. Natl. Acad. Sci., 96, 7330–7335, 1999 incorporated herein by reference-please refer to this paper for color reproductions). The UBs were cultured in the presence of the key growth factor (GDNF; see FIG. 7 ) but with different cell conditioned media: A: 3T3 fibroblast cell conditioned medium; B: immortalized UB cell conditioned medium; C: mIMCD cell conditioned medium; D: BSN cell conditioned medium. After culture, the UBs were fixed and processed for DB lectin staining. Only BSN-CM could promote extensive branching morphogenesis of the isolated UB.
FIG. 6 : GDNF plus BSN-CM is required for branching morphogenesis (Proc. Natl. Acad. Sci., 96, 7330–7335, 1999 incorporated herein by reference-please refer to this paper for color reproductions). The UBs were cultured in the presence of BSN-CM, as in FIG. 4 but with each of single growth factors present in the growth factor mixture. Several examples are shown: A: with EGF alone; B: with FGF-2 alone; C: with HGF alone; D: with GDNF alone. Only GDNF combined with BSN-CM could promote branching morphogenesis of the isolated UB.
FIG. 7 : GDNF is required for both early and late branching morphogenesis in vitro. (Proc. Natl. Acad. Sci., 96, 7330–7335, 1999 incorporated herein by reference-please refer to this paper for color reproductions) A–C: The antibodies against GDNF are neutralizing antibodies. A: UB was cultured in the presence of BSN-CM and GDNF without antibodies; B: same as A, but normal goat IgG antibody were added; C: same as A, but antibodies against GDNF were added. D–F: GDNF is required for branching morphogenesis. The UBs were initially cultured in the presence of BSN-CM and GDNF and then the cultures were washed to remove GDNF at different time points; the UBs were then continuously cultured in BSN-CM without GDNF. To ensure neutralization of residual GDNF in the culture, antibodies against GDNF were added after removal and washing of GDNF from the culture medium. D: The UB was cultured as in A, but GDNF was removed and antibodies against GDNF were added on the first day of culture; E: Same as D, but the GDNF was removed and antibodies against GDNF were added on the second day of culture; F: Same as D, but the GDNF was removed and antibodies against GDNF were added on the third day of culture (compare with structures in FIG. 3 ). All cultures were carried out until the fifth day and processed with DB lectin staining. Whenever GDNF is depleted, UB growth and branching morphogenesis is aborted, indicating that GDNF is required for both early and late branching morphogenesis in vitro.
FIG. 8 : The cultured three-dimensional tubular structure exhibits markers of UB epithelium and is functionally capable of inducing nephrogenesis when recombined with metanephric mesenchyme in vitro. (Proc. Natl. Acad. Sci., 96, 7330–7335, 1999 incorporated herein by reference-please refer to this paper for color reproductions). The UBs were cultured in the presence of BSN-CM and GDNF and then stained for various markers (A–F). A: Light microscopic phase photograph of cultured UB; B: Staining with DB lectin, a ureteric bud specific lectin which binds to the UB and its derivatives; C: Staining for vimentin, a mesenchymal marker; D: Staining for N-CAM, the early marker for mesenchymal to epithelial conversion in the kidney; E: Staining with PNA lectin, a mesenchymally derived renal epithelial cell marker; F: Staining for cytokeratin, an epithelial marker. G–I: The cultured three-dimensional tubular structure is capable of inducing nephrogenesis when recombined with metanephric mesenchyme. The isolated UB was first cultured 7–10 days as shown in G. Then, the cultured UB was removed from the ECM gel and recombined with freshly isolated metanephric mesenchyme from E-13 rat kidneys. The recombinant was cultured on a Transwell filter for another 5 days. After culture, the sample was double stained with DB lectin (FITC) and PNA lectin (TRITC) as shown in H and in the enlarged section of H shown in I. Results indicate that the in vitro cultured UB derived structures are capable of inducing nephrogenesis in vitro.
FIG. 9 : Culture of metanephric mesenchyme. Day 13 embryonic rat kidneys rudiments were microdissected to separate the ureteric bud from the metanephric mesenchyme. The metanephric mesenchyme was then placed in a Transwell tissue culture insert on top of the polycarbonate filter (3 μm pore size). Media (DME/F12) supplemented with 10% fetal calf serum (FCS) was placed in the bottom of the chamber and the entire setup was incubated at 37° C. with 5% CO 2 with 100% humidity. (A) Freshly isolated metanephric mesenchyme. (B) The same metanephric mesenchyme following 5 days in culture.
FIG. 10 : Subculture of the ureteric bud. Ureteric buds were isolated from E13 rat kidneys and grown in culture for 7 days. At the end of this culture period the ureteric bud was dissected free of the surrounding extracellular matrix and the bud was cut into pieces and subcultured under the same conditions. (A) Originally isolated ureteric bud after seven days of culture. Black box indicates piece of bud that was dissected free and subcultured. (B) Subcultured bud after 24 hrs in culture. (C) Subcultured bud after 4 days in culture. (D) Subcultured bud after 7 days in culture.
FIG. 11 : Recombination of subcultured bud with freshly isolated metanephric mesenchyme. Ureteric buds were isolated, cultured and subcultured as previously described in FIG. 10 . Metanephric mesenchymes were microdissected from E13 day rat embryonic kidneys and placed in close contact with subcultured ureteric bud as in FIG. 8 . The recombined tissues were grown in culture for 7 days. Tubular structures are evident at this time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. Introduction
In vitro cell and organ culture models for the study of collecting system development.
Several in vitro cell culture models of tubulogenesis and branching morphogenesis can be used to perform cellular and molecular analyses of these processes that can not be easily accomplished with other models for urinary tract development.
Many techniques have been used to gain insight into the cellular and molecular basis of nephrogenesis. These include genetic approaches (knockouts and transgenics), organ culture and cell culture models. Now, it is clear that each of these approaches has limitations, and it is likely that only through their combined use that the field will arrive at an accurate picture of kidney and urinary tract development. With respect to collecting system development, it is difficult to analyze the molecular processes involved in tubulogenesis and branching morphogenesis in whole animals or whole embryonic kidney organ culture, given the spatiotemporal complexity of kidney development and multiple potential interactions between numerous mesenchymally and epithelial-derived cells in varying stages of differentiation. Until a few years ago, there were no simple in vitro systems to study tubulogenesis and branching of renal or renal-derived epithelial cells. In recent years, it has become possible to analyze these processes using renal epithelial cells cultured in extracellular matrix gels under stimulation by soluble growth factors and/or conditioned medium from cells derived from the early metanephric mesenchyme.
Hepatocyte growth factor (HGF), the receptor for which is c-met, a RTK, has been known for some time to be able to induce the formation of branching tubular structures when MDCK cells (a renal epithelial cell line) are seeded in Type I collagen matrix gels. Without HGF, these cells develop into cystic structures, but in the presence of HGF, the cells form cytoplasmic processes which eventually develop multicellular branching chords and then into tubular structures. The inventors have previously demonstrated that the HGF-induced structures have apical-basolateral polarity, as determined by immunofluorescence with antisera against marker proteins for apical and basolateral surfaces of polarized tubular epithelial cells (Dev. Biol., 159, 535–548, 1993). Thus, HGF is sufficient, in the setting of the appropriate three dimensional extracellular matrix, to produce polarized tubular structures similar to those existing in the differentiated collecting ducts (Dev. Biol., 160, 293–302, 1993; Dev. Biol. 163, 525–529, 1993, Proc. Natl. Acad. Sci., 92, 4412–4416). The inventors have also developed novel cell culture models for branching tubulogenesis using both mature collecting duct cells and embryonic ureteric bud cells. The morphogenesis of embryonic UB cells is largely dependent upon growth factors other than HGF.
Nevertheless, as inventors show below, inventors have, for the first time, been able to demonstrate that the isolated ureteric bud can undergo impressive branching morphogenesis in the presence of soluble factors, though there is a subsequent requirement for contact with mesenchyme for both elongation and guidance of branching ureteric-bud derived structures, as well as nephron formation. Thus, the inventors have set up unique embryonic cell and organ culture based systems that can help dissect the cellular and molecular basis of kidney growth, morphogenesis and development. Many of these systems were first established by the inventors and have been exclusively characterized by them. Several of these systems are described below.
EXAMPLE 1
Isolation of ureteric bud (UB) epithelium and UB culture (Proc. Natl. Acad. Sci., 86, 7330–7335, 1999 incorporated herein by reference): Kidney rudiments were dissected from timed pregnant Sprague Dawley rats at gestation day 13. (The plug day was designated as day 0). The UB was isolated from mesenchyme by incubating kidney rudiments in 0.1% trypsin in the presence of 50 U/ml DNAase at 37° C. for 15 minutes, and by mechanical separation with two fine-tipped minutia pins. For culture, Transwell tissue culture plates and a polycarbonate membrane insert with 3 um pore size were used. The extracellular matrix (ECM) gel (a mixture of type I collagen and Matrigel) was applied on top of the Transwell insert. Isolated UB was suspended in the ECM gel and cultured at the interface of air and medium. All cultures were carried out at 37° C. with 5% CO2 and 100% humidity in DMEM/F12 supplemented with 10% Fetal Calf Serum (FCS). Growth factors were added as indicated elsewhere. Culture media were changed weekly if necessary.
EXAMPLE 2
Cells and conditioned media: The BSN cell line was derived from day 11.5 mouse embryonic kidney metanephric mesenchyme originally obtained from a mouse line transgenic fro the early region of SV-40/large T antigen. As described elsewhere, the BSN cells express the mesenchymal protein marker vimentin, but not classic epithelial marker proteins such as cytokeratin, ZO-1 and E-cadherin. Differences in the expression patterns of 588 genes in BSN cells have been analyzed by the inventors on commercially available cDNA grids (Am. J. Physiol.—Renal Physiol., 277, F:650–F663, 1999), and confirmed the largely non-epithelial character of BSN-cells, though it remains to be determined whether they are mesenchymal or stromal, or have characteristics of both cell types. The SV-40/large T antigen transformed UB cell line and murine inner-medulla collecting duct (mIMCD) cells have been extensively characterized before. To obtain conditioned media, a confluent cell monolayer was washed with serum-free medium, and then cultured in serum free medium for another 2–4 days. Various conditioned media were harvested after low speed centrifugation to remove cell debris and the concentrated 10-fold with a Centricon filter with 8 kDa nominal molecular weight cutoff (Millipore, Bedford, Mass.). In addition, BSN-CM was subfractioned on a heparin-sepharose affinity column (Hitrap Heparin; Pharmacia, NJ). Concentrated BSN-CM (˜10X) was applied to a heparin column. After washing the column with Hanks' balanced buffer solution, the heparin bound fraction was eluted with 2 M NaCl in Hanks' balanced buffer solution. After desalting with a PD-10 column (Pharmacia, NJ), the heparin bound fraction's final volume was adjusted to the starting volume. The heparin flow through fraction was collected and its volume was adjusted to the starting volume using a Centricon filter (8 kDa cutoff). The partially purified fractions were assayed for their effect on UB morphogenesis in the presence of GDNF.
EXAMPLE 3
The ECM gel mix: The ECM gel mix was composed of 50% type I collagen (Collaborative Biomedical Product) and 50% growth factor-reduced Matrigel® (Collaborative Biomedical Product). The procedure for gelation has been previously described in detail and is incorporated herein.
EXAMPLE 4
Induction of nephrogenesis by cultured UB: Isolated UBs were first cultured for 7–10 days as already described. Then, the cultured UB was isolated from the ECM gel by incubation with collagenase (1 mg/ml) and dispase (2 ml/ml) at 37° C. for 30 minutes, followed by mechanical separation with fine tipped minutia pins. The UB was then recombined with freshly isolated E-13 rat metanephric mesenchyme and co-cultured on a transfilter for another 5 days in DMEM/F12, plus 10% FCS.
EXAMPLE 5
Lectin staining: 1) Dolichos Bioflorus (DB) lectin: Tissues were fixed with 2% paraformaldehyde for 30 minutes at 4° C., permeabilized with 0.1% Saponin and then incubated with fluorescent conjugated DB (50 ug/ml, Vector) in a moisturized chamber for 60 minutes at 37° C. After extensive washing, tissues were post-fixed in 2% paraformaldehyde again for 5 minutes and viewed using a laser scanning confocal microscope. The specificity of DB lectin binding has been demonstrated previously. 2) Peanut agglutinin (PNA) lectin: Tissues were fixed with 2% paraformaldehyde for 30 minutes at 4° C.; blocked with 50 mM NH 4 Cl overnight at 4° C., followed by an incubation with 1% gelatin in 0.075% Saponin for 30 minutes at 37° C. After two washes with Neuraminidase buffer (150 mM NaCl, 50 mM Na-Acetate, pH 5.5), tissues were incubated with Neuraminidase (1 U/ml) for 4 hours at 37° C. and then with Rhodamine-conjugated PNA (50 ug/ml) for 60 minutes at 37° C. Tissues were post-fixed with 2% paraformaldehyde and viewed with a laser scanning confocal microscope.
EXAMPLE 6
Immunocytochemistry: Tissues were fixed with either 2% paraformaldehyde at 4° C. or 100% methanol at −20° C. Tissues were permeablized with 0.1% Saponin and non-specific binding was blocked with fetal 100% FCS***. The incubations with primary and secondary antibodies were carried out for 60 minutes at 37° C. The staining with FITC or TRITC-conjugated antibodies was viewed with a laser scanning confocal microscope.
EXAMPLE 7
Confocal Analysis: Confocal images were collected with a laser scanning confocal microscope (Bio-Rad MRC 1024, Bio-Rad, CA). Each three-dimensional picture was reconstructed from a set of 10 um serial sections, which spanned the tissue. Images were processed with Laser Sharp™ (Bio-Rad) and Photoshop™ (Adobe, CA) software.
DISCUSSION
The abovementioned examples define a new method of producing an active, functional embryonic kidney or fragment.
Immortalized UB cells have been shown by the inventors to undergo impressive morphogenesis in the presence of soluble factors (16) when seeded in extracellular matrix gels containing Type I collagen mixed with growth factor-depleted Matrigel®, a basement membrane extract derived fro EHS sarcoma cells (Proc. Natl. Acad. Sci., 86, 7330–7335, 1999 incorporated herein by reference). A conditioned medium elaborated by BSN cells (BSN-CM), an immortalized line derived from early metanephric mesenchyme that has been developed by the inventors, has been shown to induce the formation of branching tubular structures, some of which have apparent lumens; the key activity in BSN-CM was shown to be distinct from a number of growth factors known to induce morphogenesis in mature kidney epithelial cell lines. The results from these cell culture studies suggest that the program for branching morphogenesis exists within UB cells and does not require direct contact with metanephric mesenchymal cells. Reasoning that the conditions for branching morphogenesis of isolated UB tissue might be similar to this in vitro cell culture system employing a UB cell line, the inventors separated embryonic rat kidney UB from the metanephric mesenchyme prior to induction and cultured the isolated UB (free from mesenchyme) in a mixture of collagen and growth factor deleted Matrigel® ( FIG. 2 ). After trying many different conditions, dichotomous branching morphogenesis resembling the structures of the developing embryonic kidney was achieved when the isolated UB was cultured in the presence of a combination of BSN-CM and a mixture of growth factors (EGF, HGF, IGF, FGF-2 and GDNF) ( FIG. 3 ). The growth factor mixture was chosen based upon the effects of individual factors on in vitro morphogenesis of cultured UB and mIMCD cells previously performed by the inventors; HGF and EGF induce complex morphogenetic changes in UB and mIMCD cells, while IGF and FGF-2 induce some morphogenetic changes in UB cells. Because of strong genetic and cell culture data supporting the role of GDNF/cRET in early UB morphogenesis and survival of UB-derived cells, GDNF was also added to the mixture.
At gestational day 13, rat UB is a “T” shaped epithelial tubule ( FIG. 3 a ). In vivo, this single branched epithelial tubule undergoes repeated dichotomous branching and forms the “tree” shaped collecting system through interactions with metanephric mesenchyme. This epithelial-mesenchymal interaction is thought to be required for the tubular/ductal development of several organ systems, such as lung, pancreas and mammary gland. In the inventors' system, isolated UB (free from metanephric mesenchyme) can be cultured and induced to undergo branching morphogenesis in vitro. The cultured UB branched dichotomously with formation of structures that had apparent lumens. Each branch had both tubular and ampullary portions ( FIG. 3 b through d). Staining with lectins and antibodies indicated that the tubular structures remained UB-derived and epithelial in character. Both cell proliferation and branching morphogenesis appeared to occur simultaneously. In most cases, after 48 hours of culture, UB epithelial tissue started to increase in size and developed small protrusions from the “T” shaped ureteric bud. After 3–4 days of culture, those protrusions started to elongate, and the tips of the elongated structure started to branch dichotomously. The structures formed form the cultured UB revealed no staining with vimentin antibodies and peanut lectin (PNA), markers for mesenchymally derived elements, further supporting the notion that, in the appropriate milieu of soluble factors, complex branching of the UB can occur in the absence of direct contact with the metanephric mesenchyme. Moreover, growth of isolated UB was observed for up to 3–4 weeks, with many generations of branching.
BSN-CM played a critical role in this morphogenetic process ( FIGS. 4A–D ). In the absence of BSN-CM, growth factors had no effect on proliferation and branching morphogenesis of the UB ( FIG. 4B ). Only when BSN-CM was present, did the UB develop into a three-dimensional tubular structure ( FIGS. 4D and 5D ). To examine whether BSN-CM contained unique factors for the branching morphogenesis of the UB, conditioned media from different cell lines were compared. Neither conditioned medium derived from Swiss 3T3 fibroblasts (an inducer of MDCK cell branching tubulogenesis in Type I collagen) nor from UB cells or mIMCD3 cells was capable of substituting for BSN-CM ( FIGS. 5A–C ), suggesting that the BSN cells retain the ability to secrete a relatively unique factor, or set of factors, made by the metanephric mesenchyme and required for UB branching morphogenesis ( FIG. 5D ). This activity was heat-sensitive. When BSN-CM was fractionated over a heparin sepharose column, only the heparin bound fraction exhibited morphogenetic activity.
Nevertheless, the factor (or a set of factors) in BSN-CM was not sufficient to induce UB branching morphogenesis. In the absence of the growth factor mixture, the UB underwent apoptosis as determined by the TUNEL assay (data not shown). To further define conditions for in vitro UB branching morphogenesis, the Inventors examined whether any single growth factor present in the growth factor mixture could, in combination with BSN-CM, induce UB branching morphogenesis. The combination of BSN-CM and GDNF, but no other combination, was found to be sufficient to induce the formation of three-dimensional branching structures comparable to those observed with BSN-CM and the growth factor mixture ( FIGS. 6A–D ). Consistent with this observation, the combination of BSN-CM and GDNF prevented the UB from undergoing apoptosis and facilitated UB proliferation (data not shown). Since GDNF alone could not induce branching morphogenesis in the absence of BSN-CM, a factor or factors present in the BSN-CM must be required for the action of GDNF in the induction of UB branching morphogenesis. While studies from others have indicated that GDNF is involved in the initial formation of the UB , it has not been established whether GDNF is required for the further ranching morphogenesis of the UB. Therefore, the UB was first cultured in the presence of BSN-CM and GDNF, and then in the absence of GDNF after repeatedly washing away GDNF from the culture and then adding antibodies know to neutralize GDNF in the system ( FIGS. 7A–C ). Withdrawal of GDNF from the culture system blocked further UB branching morphogenesis, suggesting that GDNF is not only involved in early UB formation but also in further iterations of UB branching ( FIG. 7D–F and compare FIGS. 7E and 7F with FIGS. 3 b and 3 c ). In this regard, it is interesting to note that mesenchymal cell contact or some other soluble factor may be able to partially compensate for GDNF, at least under certain conditions in whole organ culture, since c-RET antisense oligonucleotides are not strongly inhibitory of continued branching of the UB when added after induction.
To characterize the complex tubular structures of the in vitro cultured UB, expression of several markers was examined. The cultured UB structures exhibited positive staining with DB lectin and cytokeratin antibodies, but negative staining with PNA lectin and vimentin antibodies. The expression pattern of these markers confirmed that the tubular structures formed in vitro were UB-derived ( FIGS. 8A–F ). Nevertheless, a key issue was whether the cultured UB retained the capacity for induction of nephric units in the metanephric mesenchyme. When this was tested, it was confirmed that the tubular structures resulting from the cultured UB were capable of eliciting mesenchymally-derived metanephric nephronal structures and of being incorporated into the nephric unit when recombined with the freshly isolated metanephric mesenchyme ( FIGS. 8G–I ). As shown by PNA staining, most nephrons were located at the periphery of the cultured tissue, where tips of new UB branches were forming. All formed mesenchymally-derived nephronal structures appeared connected with the tubular structures of UB. In addition, the cultured UB structures continued to respond to the inductive effect of mesenchyme by elongating further into the mesenchymal tissue ( FIGS. 8H–I ). Together, these results indicate that the structures grown in vitro are UB-derived epithelial tubules and retain induction competence even after many days of ex vivo culture. The results also suggest that while the factor(s) in BSN-CM plus GDNF may be sufficient for the initial branching processes, later events in UB morphogenesis (e.g. elongation and establishing the pattern of branching) may require contact with mesenchyme.
Thus, by utilizing the Inventors' novel model system, the Inventors have found that, in contrast to the widely held view that the complex arborization of the UB during kidney development is dependent upon direct contact between cells of the metanephric mesenchyme and cells of the UB, a substantial degree of branching morphogenesis can be mediated by soluble factors lone. Therefore, the branching program exists within the UB itself after it is formed form the Wolffian Duct, and soluble factors can trigger its initiation and continuation. No singular soluble factor, however, appears sufficient. A combination of GDNF and an activity, or set of activities, present in BSN-CM is necessary. Whether this latter activity is the same as that which induces the formation of branching tubules with lumens of UB cells in culture remains to be determined. It seems very likely that more direct mesenchymal interactions with the UB are important for establishing the direction of branching events since the cultured UB-derived structures lack directionality, and only when the culture UB was recombined with metanephric mesenchyme did directionality and elongation occur ( FIGS. 8H–I ). Epithelial-mesenchymal cell-cell contact is probably essential for the later steps in the development of UB/collecting system. Additional mechanisms are likely to be involved in the formation of junctions between mesenchymally-derived nephronal segments and collecting tubules and the development of tertiary structures of the collecting tubule, such as the formation of arcades. Moreover, contact with the mesenchyme might provide a “stop” mechanism for kidney growth since Inventors found that the isolated UB continued to grow in vitro as long as soluble factors were provided.
Inventors' data also clarify the role of GDNF in kidney development. To date, GDNF has been implicated in initial UB outgrowth and early survival, but its role in branching morphogenesis of the UB has been debated. Inventors' data indicate that GDNF, in combination with factors in BSN-CM, supports true morphogenesis of the UB, at least in vitro. GDNF is required for not only the initial outgrowth but also the subsequent branching morphogenesis of the UB.
Finally, these results suggest that it be worth reevaluating the role of cell contact versus soluble factors in a wide variety of epithelial tissues where intimate cellular interactions between epithelial and mesenchymal tissues are thought to play a crucial inductive role, particularly with respect to branching morphogenesis. In the developing kidney, and perhaps in many of these other tissues, the role of cell contact may be facilatory rather than crucial for early branching morphogenesis per se, although it may be essential for the establishment of vectoriality and later events in differentiation (Proc. Natl. Acad. Sci., 86, 7330–7335, 1999 incorporated herein by reference).
While the present invention has now been described in terms of certain preferred embodiments, and exemplified with respect thereto, one skilled in the art will readily appreciate that various modifications, changes, omissions and substitutions may be made without departing from the spirit thereof. It is intended, therefore, that the present invention be limited solely by the scope of the following claims. | A method for constructing a stable bioactive mammalian embryonic kidney is described herein. A kidney so constructed requires no artificial support, nor porous man made membranes or tubing to effectuate its biological function of filtering body fluids. A single donor embryonic kidney, or fragment thereof, can produce a great number of functional kidneys suitable for treating subjects with various kidney disorders. It is anticipated that said in vitro produced kidney would be less, or not at all, antigenic when transplanted into a subject, because of its embryonic character and artificial propagation in culture. This method of producing a functional organ can be useful in cloning other organ structures containing inducible epithelial tissues. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation-in-part of co-pending application Ser. No. 09/728,955, filed Dec. 1, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the golf clubs and, more particularly, to golf club heads.
[0003] Modern golf clubs have typically been classified as either woods, irons or putters. The term “wood” is a historical term that is still commonly used, even for golf clubs that are constructed of steel, titanium, fiberglass or other more exotic materials, to name a few. The term “iron” is also a historical term that is still commonly used, even though those clubs are not typically constructed of iron, but are rather constructed of many of the same materials used to construct “woods”.
[0004] Many advancements have been achieved, particularly over the past couple of decades, to make it easier to hit longer and straighter shots with woods and irons. In general, golf clubs are now designed to be more forgiving, so that shots that are struck less than perfectly will still have fairly consistent distance and directional control. Moreover, club heads now commonly are constructed of combinations of materials, to attempt to optimize the ball flight desired by a particular type of player.
[0005] One particular improvement that relates to irons is the use of perimeter weighting, whereby a disproportionate amount of the total weight of a club head is positioned behind and proximate the perimeter of the club head's striking face, thereby creating a cavity immediately behind the striking face. The cavity is formed by the club face wall and the weight that is placed around and behind the club face. This type of club is typically referred to as a “cavity back” iron. By moving the weight peripherally away from the center of gravity (CG) of the club head, the club is made to be more forgiving on off-center hits, resulting in more consistent distance and directional control. Further, perimeter weighting generally increases the moment of inertia about the club's CG, resulting in less twisting due to off-center hits, and more accurate shots.
[0006] There are so-called “hollow” irons that incorporate a rear wall that is spaced from the front striking face. This also increases the moment of inertia about the club's CG and is found to benefit some higher handicap golfers. Some hollow irons more closely resemble fairway woods in cross-sectional shape, while other hollow irons may resemble cavity back irons in their cross-section.
[0007] Another improvement is the use of lighter and stronger materials, which enables club designers to move the CG to an optimal location on a wood or iron. Such a movement can make the club either easier to hook or to fade, if the movement is made either closer to or farther from the hosel. Similarly, if the CG is moved higher or lower with respect to the club face, the golf ball launch conditions can be altered. For instance, lowering the CG generally makes it easier to get the ball airborne for either an iron or a wood. Conversely, raising the CG promotes a more boring ball flight that generally leaves the club face at a lower launch angle.
[0008] Generally, it has been shown that it can be advantageous for players with higher handicaps to use clubs with a lower CG. This is especially true for long irons, such as for example a 3 -iron. Club designers have responded to this prospective advantage by lowering the CG of both woods and irons for clubs intended for higher handicap players. The most common way that this has been accomplished for irons is to move as much weight as possible to the area proximate the sole of the club. This results in a concentration of weight proximate the sole. Often, for these types of irons, the transition from the cavity to the weight on the sole is abrupt, compared to traditional irons having a smoother transition. When viewing a cross-section of the lower portion of the club face, a dramatic change in the thickness of the face nearer the sole often is apparent in such sole-weighted club heads.
[0009] While it is recognized that the lower CG of the improved clubs can be beneficial, such a lowering can have negative side effects. First, the concentrated mass proximate the sole can increase the stiffness of the club head. This can cause a noticeable change in the club's feel. Feel is a term that is generally used by skilled practitioners to denote a subjective expression of the way a club feels to one's hands when striking a golf ball, or the way it sounds. Feel is generally perceived as audible to tactile feedback to the golfer. Different sensations due to striking the ball in different locations on the club face may make a club less desirable to a potential user.
[0010] Second, the weight concentration proximate the sole can lead to different levels of flex at different points on the club face. The area of the face proximate the thickest portion of the sole is likely to flex less than the area proximate the inner areas of the striking face. Such a change in flex can adversely affect performance.
[0011] Third, the weight concentration can lead to excess vibration, which can adversely affect the feel of the golf club, including the sound made by the club.
[0012] It should be appreciated from the foregoing description that there is a need for an improved golf club head that creates a more consistent flex when striking the ball, improves the club's feel, and reduces vibration. The present invention satisfies this need and provides further related advantages.
SUMMARY OF THE INVENTION
[0013] The present invention provides a solution to counteract the negative side effects described above, by allowing club designers to design a club with an optimal center of gravity, while at the same time lowering the stiffness proximate the sole, creating more consistent flex while striking the ball, improving the feel of the club and reducing vibration.
[0014] According to a preferred embodiment, a golf club head has a body with a striking face, a rear cavity, a hosel and a sole portion. The rear cavity has a cavity wall and a cavity rim, and a recess having a wall is formed proximate the rear cavity. The recess extends generally from the rear cavity toward a bottom of the sole portion. An insert is located within the recess and includes a core and an intermediate layer that at least partially separates the core from the recess wall. The intermediate layer has a hardness and a modulus of elasticity that are less than that of the core, such that when the golf club head is used to strike a golf ball, the resulting vibrations are dissipated by compression of the intermediate layer and friction between the core and the intermediate layer.
[0015] In another preferred embodiment, a golf club head has a body with a striking face, a rear cavity and a sole portion. A recess is formed in the rear cavity and extends generally toward a bottom of the sole portion. There is at least one aperture formed proximate the recess and extending generally from the recess toward the bottom of the sole portion. A cell is inserted within the aperture and has a pin and an outer sleeve. The sleeve has a hardness and a modulus of elasticity that are less than that of the pin, such that when the golf club head is used to strike a golf ball, the resulting vibrations are dissipated by compression of the sleeve and friction between the pin and the sleeve.
[0016] Yet another preferred embodiment includes a main body having a front perimeter, a hosel, a rear portion forming a rear cavity and a sole portion. A first recess is formed in the sole portion and extends generally from the rear cavity toward a bottom of the sole portion. The first recess has a recess wall. A striking face is attached to the front perimeter of the main body, and a hollow portion is formed between the striking face and a wall of the rear cavity. A core and an intermediate layer are located within the first recess, with the intermediate layer at least partially separating the core from the recess wall. A weight is located in the sole portion having a density greater than or equal to a density of the core. The intermediate layer has a hardness and a modulus of elasticity that are less than that of the core, such that when the golf club head is used to strike a golf ball, the resulting vibrations are dissipated by compression of the intermediate layer.
[0017] For purposes of summarizing the invention and the advantages achieved over the prior art, certain advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
[0018] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a rear view of a first preferred embodiment of a golf club head in accordance with the invention.
[0020] [0020]FIG. 1A is a cross-sectional view of the golf club head of FIG. 1, viewed along line A-A, depicting an insert assembly in the recess in the cavity rim and sole bar.
[0021] [0021]FIG. 1B is an exploded view of the golf club head of FIG. 1.
[0022] [0022]FIG. 2 is an exploded view of a second preferred embodiment of a golf club head similar to FIG. 1.
[0023] [0023]FIG. 3 is a rear view of a third preferred embodiment of a golf club head in accordance with the invention.
[0024] [0024]FIG. 3A is a cross-sectional view of the golf club head of FIG. 3, viewed along line A-A, depicting an insert assembly in the recess in the cavity rim and sole bar.
[0025] [0025]FIG. 3B is an exploded view of the golf club head of FIG. 3.
[0026] [0026]FIG. 4 is a rear view of a fourth preferred embodiment of a golf club head in accordance with the invention.
[0027] [0027]FIG. 4A is a cross-sectional view of the golf club head of FIG. 4, viewed along line A-A, depicting an insert assembly in the recess in the cavity rim and sole bar.
[0028] [0028]FIG. 4B is an exploded view of the golf club head of FIG. 4.
[0029] [0029]FIG. 5 is a rear view of a fifth preferred embodiment of a golf club head in accordance with the invention.
[0030] [0030]FIG. 5A is a cross-sectional view of the golf club head of FIG. 5, viewed along line A-A, depicting an insert assembly in the recess in the cavity rim and sole bar.
[0031] [0031]FIG. 5B is an exploded view of the golf club head of FIG. 5.
[0032] [0032]FIG. 6 is a cross-sectional view of a sixth preferred embodiment of a golf club head similar to FIG. 5.
[0033] [0033]FIG. 7 is a cross-sectional view of a seventh preferred embodiment of a golf club head similar to FIG. 5.
[0034] [0034]FIG. 8 is an exploded view of a eighth preferred embodiment of a golf club head similar to FIG. 5.
[0035] [0035]FIG. 8A is a cross-sectional view of the assembled golf club head of FIG. 8, depicting an insert assembly in the recess in the cavity rim and sole bar.
[0036] [0036]FIG. 9 is a cross-sectional view of a ninth preferred embodiment of a golf club head similar to FIG. 1.
[0037] [0037]FIG. 10 is a cross-sectional view of a tenth preferred embodiment of a golf club head similar to FIG. 1 or FIG. 4.
[0038] [0038]FIG. 11 is a cross-sectional view of another preferred embodiment of a golf club head similar to FIG. 6.
[0039] [0039]FIG. 12 is a cross-sectional view of another preferred embodiment of a golf club head.
[0040] [0040]FIG. 13 is a view of elements of the insert for the golf club head of FIG. 13.
[0041] FIGS. 14 A-B are cross-sectional views of other preferred embodiments of a golf club head of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] Referring now to a first embodiment of the present invention shown in FIGS. 1 and 1A, there is shown a golf club head 10 that is similar to many cavity back club heads that are known in the art. The club head 10 includes a body 11 having a heel 12 , a toe 13 , a sole 14 , a front striking face 15 , a top line 16 , and a hosel 17 . The body 11 also has a rear cavity 20 that has a cavity wall 21 that is substantially parallel to the striking face 15 .
[0043] The cavity 20 includes a cavity rim 22 that extends substantially rearwardly from the cavity wall 21 proximate the heel 12 , toe 13 , sole 14 and top line 16 , as shown in FIGS. 1 and 1A. The club head 10 has a perimeter weighting 25 that comprises a mass of material that extends rearwardly from the entirety or a portion of the perimeter of the club head proximate the cavity rim 22 . The perimeter weighting 25 includes a sole bar 26 or mass concentration located proximate the sole 14 so as to provide the desired weight distribution characteristics.
[0044] The perimeter weighting 25 may take various shapes as it wraps from a perimeter of the striking face 15 to the cavity rim 22 . As shown in FIG. 1A, a cavity transition 23 is located between the cavity rim 22 and the sole 14 . The transition 23 may be radiused or may comprise a series of planar surfaces. The body 11 has a raised cavity center weight 27 that protrudes rearwardly from the cavity wall 21 and that is defined by cavity step downs 28 , 29 , toward the heel 12 and toe 13 , respectively. Alternatively, the cavity wall 21 could be substantially flat (see FIG. 5) or have other shapes to create different performance characteristics and different weight distribution.
[0045] The body 11 is preferably formed of a cast stainless steel, although other known materials known to those skilled in the art may be used. The striking face 15 may be integrally cast with the body 11 , or it may be separately formed and attached to a main body portion 11 ′ comprising the heel 12 , toe 13 , top line 16 , sole 14 , and hosel 17 (see FIGS. 5A, 6 and 7 ). Alternatively, the striking face 15 may be integrally cast or forged with the hosel 17 (not shown) and attached to the remainder of the club head body 11 . A preferred attachment method for the striking face 15 is welding, although other methods known to those skilled in the art may be used.
[0046] As shown in FIGS. 1A and 1B, the body 11 has a recess 60 formed in the sole bar 26 proximate the cavity rim 22 . A preferred method of forming the recess is by casting the recess 60 with the body 11 , although the recess 60 may also be machined into the cast body 11 . The recess 60 extends longitudinally between the heel 12 and the toe 13 . The recess 60 preferably extends downwardly and slightly forward toward the striking face 15 for ease of manufacturing. The recess 60 is defined by a recess wall 61 and a bottom 68 . The bottom 68 of the recess 60 is preferably distanced from the outer surface of the striking face 15 by at least the minimum thickness of the cavity wall 21 .
[0047] An insert assembly 30 is located in the recess 60 , as shown in FIGS. 1A and 1B. The assembly 30 includes a cartridge 32 having apertures 34 that closely receive a plurality of pins 42 . A badge 50 is used to cover the cartridge 32 and pins 42 . Five similarly sized pins 42 are included in the assembly 30 and span a lower central region of the cavity rim 22 proximate the center weight 27 .
[0048] More or less pins 42 , having similar or different shapes, volumes and densities, may be substituted according to the vibration damping, stiffness, feel and weight distribution characteristics that are desired. For ease of manufacture, the pins are preferably cylindrical; however, alternative shapes such as cubes or the like may be used. The apertures are sized and shaped according to the dimensions of the pins. A single pin having a rectangular cross-section generally conforming to the shape of the recess may also be used in the cartridge of the assembly.
[0049] The cartridge 32 is formed of an elastomer, including, for example, thermoplastic materials such as urethane. Other materials may be utilized, so long as the material has a hardness and a modulus of elasticity that are lower than that of the pins 42 . The shape and size of the cartridge may be adjusted according to the desired performance characteristics mentioned previously. The cartridge may be constructed of a translucent material allowing the pins 42 to be visible (see FIG. 4).
[0050] The preferred pin 42 may be constructed of tungsten, nickel, aluminum or stainless steel, for example. Other materials may be used, so long as the material is sufficiently dense and has a relatively high modulus of elasticity. The pin 42 is preferably constructed of material having a density at least as high as the material of the body 11 and may be higher than the material forming the striking face 15 . Preferably, a shallow recess 52 is provided proximate the upper end of the recess wall 61 . A shoulder 54 is formed and receives the badge 50 . The depth of the recess 52 is preferably such that the exterior, visible surface of the badge 50 is flush with the cavity rim 22 when the badge is seated on the shoulder 54 . It is understood, however, that the recess 52 may be omitted and the badge 50 may be placed directly atop the assembly 30 and either raised from or flush with the cavity rim 22 . An adhesive may be used to secure the badge 50 over the recess 52 and/or the assembly 30 . In addition, an intermediate layer of metal or plastic material (not shown) may be used between the badge 50 and the insert 30 .
[0051] The badge 50 may be decorative as well as functional. For example, the badge may be constructed of a translucent material allowing the assembly 30 to be viewed through the badge 50 . Or, slits or cutouts may be provided on the badge 50 to allow viewing of the assembly 30 . Alternatively, the badge 50 may include embossing, engraving or the like, as known to those skilled in the art. As such, metals such as nickel as well as plastic materials may be used for the badge 50 .
[0052] A second preferred embodiment is shown in FIG. 2 and has grooves 35 formed along a bottom of the cartridge 32 ′. Corresponding ribs 36 are formed on the bottom 68 and are received in the corresponding grooves 35 . The ribs may be used to reinforce the lower region of the striking face 15 , add some additional mass in the sole bar 16 , and/or aid in securing the cartridge 32 ′ by providing additional surface area for an adhesive, if used.
[0053] Another preferred embodiment shown in FIGS. 3, 3A and 3 B has an insert assembly 30 ′ that includes cells 40 that are inserted into separate apertures 64 formed in the sole bar 26 . Each cell includes a pin 42 that fits into an aperture 43 at a proximal end 45 of a sleeve 41 . References to the embodiments described herein use like numerals to refer to like elements and their descriptions. In this embodiment the plurality of sleeves 41 are similar in material and function as the single cartridge 32 of the prior embodiment. Instead of a single recess 60 , the plurality of apertures 64 are formed along a similar region as shown by referring to FIGS. 1 and 3. Again, a badge 50 is preferably used to cover the cells 40 of the assembly 30 ′.
[0054] As shown in FIG. 3B, each pin 42 has a proximal end 44 and a distal end 46 . Each sleeve 41 has its aperture 43 sized to easily accept a pin 42 . The sleeve 41 has an open proximal end 45 and a closed distal end 47 . The length of the sleeve 41 is about the same as the length of the pin 42 so that the distal end 46 of the pin 42 may contact the interior of the distal end 47 of the sleeve 41 . A lip 49 at the proximal end 45 of the sleeve 41 may be used to capture the proximal end 44 of the pin 42 and aid in its retention prior to the insertion of the cell 40 into the aperture 64 .
[0055] Referring now to FIG. 3A, it may be seen that the cell 40 preferably does not contact a bottom 66 of the aperture 64 . Also, the proximal ends 44 , 45 of the pin 42 and sleeve 41 , respectively, are spaced slightly below the badge 50 . The badge 50 is supported in the shallow recess 52 by shoulder 54 . This construction is helpful during the manufacture of the club head.
[0056] An alternative embodiment for a club head in accordance with the present invention is shown in FIGS. 4, 4A and 4 B. A cartridge 132 includes an upper portion 130 that extends onto a lower portion of the center weight 27 and is uncovered. The pins 42 of the assembly 30 are embedded in holes 131 through a lower portion 133 of the cartridge 132 and are made visible through the use of a translucent material for the cartridge 132 . The material of the cartridge 132 may also comprise a high density polymer.
[0057] The features of this embodiment are further made obvious by the concave shaping of the upper portion 130 , such that the assembly 30 does not lie flush with the cavity rim 22 . A variation of this embodiment is for the upper portion 130 of the cartridge 132 to resemble the badge 50 of FIG. 1 by being substantially planar—or alternatively convex—instead of being concave; the upper portion 130 is integral with the lower portion 133 of the cartridge 132 . The pins 42 are embedded within the cartridge using methods, such as press-fitting, known to those skilled in the art. The cartridge is preferably secured with adhesive tape in the bottom of the recess 60 .
[0058] Another club head 10 constructed in accordance with the present invention is shown in FIGS. 5, 5A and 5 B and has a planar cavity wall 21 surrounded by a perimeter weighting 25 . It has a front recess 70 that is formed by the main body 11 ′ and enclosed by the striking face 15 ′. A rear 19 of the striking face 15 ′ is supported by a periphery 18 formed by a front edge of the heel 12 , toe 13 , sole 14 and top line 16 of the body 11 ′.
[0059] Alternatively, the striking face 15 ′ may be supported by a ledge (not shown) surrounding the recess 70 that is formed along the periphery 18 of the body 11 ′. The striking face 15 ′ is preferably welded to the body 11 ′. This construction allows higher deflection of the face at impact since the material of the striking face 15 ′ may have a lower modulus of elasticity than the material of the main body 11 ′, and/or the striking face 15 ′ may be formed thinner than the striking face 15 of conventional cavity back irons.
[0060] The insert assembly 30 ′ is constructed in the sole bar 26 with the damping cells 40 covered by a badge 50 . Modifications to this construction may be made in any manner previously described, such as the substitution of the cells 40 with a cartridge 32 and pins 42 of the alternate insert assembly 30 . Similarly, the badge 50 may be constructed to overlie a portion of the cavity wall 21 , or a recess 60 similar to FIG. 4 may be formed up to a lower part of cavity weight 27 with the badge covering the top of the cartridge.
[0061] A variation of the embodiment of FIG. 5A is shown in FIG. 6 and also has a front recess 70 that is closed by the striking face 15 ′. A lower end of the recess 70 includes a slot 72 that has a weight 80 placed within it. An adhesive is preferably used to secure the weight 80 within the slot 72 . The slot 72 is formed in the sole bar 26 below the insert assembly 30 / 30 ′, and it may extend partially or entirely along the length of the insert assembly 30 / 30 ′. The slot 72 extends rearwardly from the front recess 70 in a directly generally parallel to the sole 14 .
[0062] Yet another variation of the club head of FIG. 5A is shown in FIG. 7 and also has a front recess 70 that is closed by the striking face 15 ′. The cavity wall 21 may include a center weight 27 or may be substantially flat. A recess 98 is formed in a central lower portion of the cavity 20 that includes a part of the cavity wall 21 , the cavity rim 22 and the transition 23 .
[0063] Within the recess 98 is an insert assembly 90 that includes a cartridge 94 and weight 96 along with a much smaller badge 99 than previously described. An upper section 91 of the insert assembly 90 replaces the portion of the cavity wall 21 , a middle section 92 replaces a portion of the cavity rim 22 , and a lower section 93 replaces a portion of the cavity transition 23 . The badge 99 is purely decorative and preferably metallic. It has a logo engraved or embossed on its outer surface.
[0064] The weight 96 is preferably embedded within the cartridge 94 using methods known to those skilled in the art. The materials of the cartridge 94 and weight 96 are chosen from the options previously described. There may be one or a plurality of weights 96 embedded within the cartridge. The mass of the sole bar 26 that is removed by the formation of the recess 98 is substantially replaced or increased by the mass of the weight 96 . Although the weight 96 is shown in a lower portion 97 of the cartridge 94 generally parallel to the sole 14 , it may also extend into an upper portion 95 of the cartridge 94 . An adhesive is preferably used to secure the assembly 90 within the recess 98 .
[0065] The embodiments of FIGS. 5, 6, and 7 having the recess 70 behind the striking face 15 / 15 ′ provide a more rearward center of gravity that may be beneficial to some golfers. Like the embodiments of FIGS. 1 - 4 , they also provide improved flex, feel and vibration damping properties over conventional club heads. The embodiment of FIG. 6, in particular, is more easily manufactured as a hollow iron. Although, the second weight 80 may be inserted and then the striking face 15 ′ may be attached such that the entire rear 19 of the striking face 15 ′ contacts the cavity wall 21 and there is no hollow formed in the club head.
[0066] [0066]FIGS. 8 and 8A depict yet another preferred embodiment similar to the hollow constructions of FIGS. 5, 6 and 7 . As in FIG. 6, an additional weight 82 is included. The insert assembly 31 ″ thus includes pins 42 , a cartridge 32 and the weight 82 . Preferably the material of the weight 82 is a tungsten powder polymer, although any material may be used so long as it has a density greater than that of the body. The inclusion of the weight 82 in the sole bar 26 allows additional options with regard to the weight distribution of the club head 10 and the resultant flex and damping properties.
[0067] The weight 82 is placed within the recess 60 , proximate the cartridge 32 and pins 42 . The weight 82 may be located as shown at the bottom of the recess; however, it may alternatively be placed above the pins, as desired. In addition, cells 40 may be used, wherein a plurality of apertures 64 are provided in the sole bar to receive the cells 40 . The weight 82 may include a corresponding number of smaller weight elements co-located within the apertures 64 with the cells 40 , or a single, adjoining recess for the weight 82 may be included above the apertures and cells.
[0068] Another embodiment shown in cross-section in FIG. 9 preferably comprises 5 pins 42 that are closely received in apertures of a cartridge 232 . The cartridge 232 is preferably formed of a loaded polymer, such as tungsten powder in a nylon or urethane resin. A lower surface 234 of the cartridge 232 is shaped to conform to the bottom surface of the recess 60 formed in the rear of the club head. It is understood that the geometry of the recess 60 is at least partly dictated by the loft angle of the club head and its effect on the shape of the sole bar 26 .
[0069] A cover 230 is preferably formed of a clear polymer and may be of a lesser density that the lower cartridge portion. The cover 230 has mating apertures to closely receive the pins 42 and thereby secure them. An adhesive is preferably used between the contacting surfaces of the cover 230 and cartridge 232 . An upper surface 222 of the cover 230 is contoured for a smooth transition along the cavity rim 22 .
[0070] The embodiment of FIG. 10 depicts an opening 200 provided at an upper end 206 of a cartridge 202 . A plurality of pins 42 or a weight 204 may be placed within the cartridge 202 . The weight 204 may comprise a single or multiple elements, such as tungsten bars. The cartridge 202 is preferably formed of a thin, high density polymer or standard urethane that accepts the pins or weight without undue effort during club head manufacture. The opening 200 may comprise a single slit at the upper end, or the opening 200 may comprise a plurality of apertures. For a plurality of apertures, a lower end 208 of the cartridge 202 may have at least one opening for insertion of the pins 42 or weight 204 .
[0071] A variation of the embodiment of FIG. 6 is shown in FIG. 11. An insert assembly 30 ( 30 ′) is provided at a lower portion of the cavity rim 22 . Instead of a slot 72 extending rearwardly from a lower end of the recess 70 , a slot 172 is formed in the perimeter weight 25 of the sole bar 26 through the cavity transition 23 . A weight 80 is closely received in the slot 172 and may be further secured with adhesive.
[0072] The embodiment of FIG. 12, with its insert assembly 30 ″ shown separately in FIG. 13, has an optional opening 200 for viewing of the assembly 30 ″. The insert assembly 30 ″ preferably comprises pins 42 embedded within a cartridge 210 and protected by a cover 150 . Because the cover 150 must endure the same impact forces as the sole bar 26 and keep out debris from the recess 160 , the material of the cover preferably comprises a metal having a density approximately equal to or greater than the material of the club head body 11 ′.
[0073] Two similar embodiments are shown in FIGS. 14A and 14B, comprising a dual weight configuration within a low density cartridge 240 , 250 . A weight assembly 330 configured as in FIG. 14A provides a higher mass contribution to the club head than the assembly 330 of FIG. 14B. Also, the assembly 330 of FIG. 14A is behind a greater area of the recess 70 and striking face 15 ′ than the assembly 330 of FIG. 14B.
[0074] The cartridge 240 , 250 is preferably formed of a polymer with a density of approximately 1 g/cc. The cartridge 240 includes an open lower end 334 having a lip 336 to aid in maintaining weights 84 , 86 in place during manufacture. The cartridge 250 includes an open end 338 without a lip 336 . In the weight assembly 330 the smaller weight 84 is located between the cartridge 240 , 250 and the larger weight 86 . Weight 84 preferably comprises a material such as aluminum having a density of about 2.7 g/cc, while weight 86 preferably comprises a material having a significantly larger density, such as 18 g/cc or so. Manipulation of the club head center of gravity may be made by changing the places of the two weights 84 , 86 within the cartridge 240 , 250 . Also, the cartridge 240 may be used for the assembly 330 in the cavity transition 23 instead of the cartridge 250 ; similarly, the cartridge 250 may be used for the assembly 330 in the cavity rim 22 instead of the cartridge 240 .
[0075] The embodiments of FIGS. 9 - 14 B are shown and described with reference to a body 11 ′ having a front recess 70 for receiving a separate striking face 15 ′; however, the present invention does not preclude these embodiments having a body 11 integrally including the striking face 15 . Although the invention has been disclosed in detail with reference only to the preferred embodiments, those skilled in the art will appreciate that golf club heads can be made without departing from the scope of the invention. Accordingly, the invention is defined only by the claims set forth below. | A golf club head is disclosed that comprises a body having a striking face, a rear cavity and a sole bar, wherein a recess is formed in the sole bar that extends generally from the rear cavity. An insert is located within the sole recess, the insert including a core and an intermediate layer that separates the core from the recess wall. The intermediate layer has a hardness and a modulus of elasticity that are less than that of the core, such that when the golf club head is used to strike a golf ball, the resulting vibrations are dissipated by compression of the intermediate layer and movement of the core with respect to the intermediate layer. | 0 |
BACKGROUND OF THE INVENTION
Nitroalcohols and their preparation are well known. Nitroparaffins or nitroalkanes that contain a hydrogen atom on the alpha carbon enter into condensation reactions of the aldol type to produce nitroalcohols. For instance, nitromethane condenses with propionaldehyde in alkaline solution to give 1-nitro-2-butanol. Tertiary nitroparaffins lack an alpha hydrogen and, therefore, can neither be deprotonated by alkali nor enter into condensation reactions. Preparation of nitroalcohols by condensing aldehydes with nitroparaffins dates back to at least 1900.
An article by Vanderbilt and Hass entitled "Aldehyde-Nitroparaffin Condensation" in Industrial and Engineering Chemistry, Vol. 32, No. 1, January 1940, pp. 34-38, provides some details relating to the preparation of nitroalcohols by condensing a nitroparaffin with an aldehyde in alkaline medium. If the nitroparaffin is secondary, there is only one alpha hydrogen atom which reacts with one mole of an aldehyde whereas if the nitroparaffin is primary, there are two alpha hydrogen atoms which react with two moles of an aldehyde. At middle of p. 35 of this article, preparation of 5-nitro-4-octanol is described whereby 2 moles of 1-nitrobutane, 100 cc of alcohol, and 4 cc of 10N sodium hydroxide solution were initially placed into a flask. Then, 2 mols of butyraldehyde were added slowly to the flask while agitating contents thereof and while maintaining reaction temperature at 30°-35°. Additional aldehyde with water was later added and the solution was allowed to stand 4 days, following which, the alkali was neutralized with hydrochloric acid and the mixture was distilled which yielded 5-nitro-4-octanol. Needless to say, the 4 days it took to prepare the nitroalcohol was excessive and unacceptable for a commercial process.
SUMMARY OF THE INVENTION
This invention relates to preparation of nitroalcohols by reacting in an organic solvent a nitroparaffin and an aldehyde in the presence of a trialkyl phosphine of the formula R 3 P where each R is individually selected from alkyl, aralkyl, hydroxyalkyl, cyanoalkyl, and cycloalkyl groups. The presence of a trialkyl phosphine reduces reaction time to less than about 5 hours whereas in its absence, reaction time is on the other of days.
DETAILED DESCRIPTION OF THE INVENTION
The reaction of a nitroparaffin with an aldehyde in alkaline medium has been used for nearly a century to produce nitroalcohols. The problem with this reaction has been an excessive reaction time. The IEC article noted above discloses that more than 4 days was required to react 1-nitrobutane with butyraldehyde in alkaline medium to produce 5-nitro-4-octanol. It has been discovered that the use of a trialkyl phosphine in such a reaction can unexpectedly reduce the reaction time to less than about 5 hours.
The reaction described herein essentially corresponds to the prior art reaction with the exception that it is carried out in the presence of a small amount of a trialkyl phosphine catalyst and there is no requirement to add an alkaline material to the reaction medium. The reaction between a secondary nitroparaffin and an aldehyde can be carried out in the temperature range of about room temperature to the boiling point of the solvent, preferably 30° to 50° C. The reaction can be generally represented as follows: ##STR1## If nitroparaffin is a primary nitroparaffin, then 2 moles of an aldehyde are reacted with the same aldol reaction taking place at the second alpha hydrogen. Generally, therefore, one mole of an aldehyde will react with each alpha hydrogen on the nitroparaffin.
In the above reaction, R 1 , R 2 and R 3 can be individually selected from hydrogen, alkyl and hydroxyalkyl groups of 1 to 12 but preferably 1 to 6 carbon atoms, and aralkyl groups of 7 to 15 but preferably 7 to 10 carbon atoms. Each of the R groups in the phosphine catalyst can be individually selected from alkyl and hydroxyalkyl groups of 1 to 12 but preferably 1 to 6 carbon atoms, aralkyl groups of 7 to 15 but preferably 7 to 10 carbon atoms, cyanoalkyl groups containing 2 to 13 but preferably 2 to 7 carbon atoms, and cycloalkyl groups containing 5 to 8 but preferably 5 to 6 carbon atoms in the ring structure and 1 to 12 but preferably 1 to 6 carbon atoms in the alkyl group.
The trialkyl phosphine catalysts can be used in amount of 0.5 to 5 mole%, preferably 1 to 3 mole%, based on nitroparaffin. Specific examples of the catalysts include tri-n-butyl phosphine, triethyl phosphine, tri-n-propyl phosphine, tri-n-octyl phosphine, tris-2-cyanoethyl phosphine, and the like.
Any suitable solvent can be used to facilitate contact between the reactants. Suitable solvents include organic solvents that can be used in amount ranging from about 10 parts to 500 parts, preferably 20 to 200 parts, per 100 parts of the reactants, all on weight basis. Specific examples of suitable solvents that can solubilize the product include isopropanol, toluene, tetrahydrofuran, methylene chloride, and the like.
Pursuant to the invention described herein, nitroalcohols, and beta-nitroalcohols specifically, can be prepared by reacting a nitroparaffin with an aldehyde, including paraformaldehyde. The reaction is conducted in presence of an organic solvent at about room temperature to the boiling point of the solvent but preferably at 30° to 50° C., and in the presence of a trialkyl phosphine catalyst. The catalyst is used at a level of 0.5 to 5 mole%, preferably at 1 to 3 mole%. The reaction is completed in 0.1 to 5 hours, preferably 0.5 to 2 hours, when the exotherm subsdies. The solvent is removed and the product can be recrystallized or distilled.
The preparation procedure involves the addition with mixing of a nitroalkane, an aldehyde, a solvent, and a small amount of the catalyst to a reaction vessel. An exotherm is generated instantly which starts to subside in about 10 minutes to 1 hour. To maintain reaction mixture at the desired temperature, external heat is applied. After about one-half hour, all of the aldehyde goes into solution and the reaction mixture becomes viscous indicating completion of the reaction.
Nitroparaffins, the reactants used in the preparation of nitroalcohols, can be made by heating alkanes in a vapor state with vapors of nitric acid at about 420° C. The nitration of propane, for instance, yields 1-nitropropane and 2-nitropropane. This mixture of nitro compounds is separated by fractional distillation into individual products which can be used as solvents or as starting materials for chemical syntheses.
The nitroparaffins or the nitroalkanes are colorless liquids of an agreeable odor. They are sparingly soluble in water but dissolve easily in most solvents. They distill without decomposition and, in contrast to the alkyl nitrates, explode with difficulty. Their boiling points are considerably higher than those of the isomeric alkyl nitrites.
The aldehydes, which are also reactants in the preparation of nitroalcohols described herein, are well known and commercially available materials. There is no limitation on the aldehyde that can be employed in preparing nitroalcohols. The reaction proceeds by condensation of an aldehyde with a nitroparaffin by extraction of an alpha hydrogen which combines with the oxygen on the aldehyde to form a hydroxyl group and the alpha carbon of the aldehyde becomes bonded to the nitroparaffin carbon which has attached thereto the nitro group.
The invention described herein will now be illustrated especially with respect to the use of a trialkyl phosphine catalyst in the preparation of beta-nitroalcohols by reacting, in a solvent, a nitroparaffin containing an alpha hydrogen and an aldehyde.
EXAMPLE 1
This example demonstrates the reaction of 2-nitropropane with paraformaldehyde in the pressence of tri-n-butyl phosphine catalyst, conducted in isopropanol solvent. The product was 2-methyl-2-nitro-1-propanol. The reaction can be depicted as follows: ##STR2##
Preparation procedure involved the addition to a reaction vessel 0.1 mole of 2-nitropropane, 0.1 mole of paraformaldehyde, 40 mls of isopropanol solvent, and 0.002 mole of tri-n-butyl phosphine catalyst. Additions of the materials to the reaction vessel were made with continuous agitation. Upon addition of the catalyst, an exotherm was instantly generated and when it started to subside in about 10 minutes, external heat was applied to maintain reaction temperature at 35° to 40° C. After about one-half hour, all paraformaldehyde went into solution and the reaction mixture became viscous, indicating completion of the reaction. The product solidified on standing after removal of solvent. Total reaction time was about 3/4 of an hour.
EXAMPLE 2
Following the procedure set out in Example 1, above, 0.1 mole of nitroethane was reacted with 0.2 mole of paraformaldehyde in isopropanol solvent in the presence of t-n-butyl phosphine catalyst. The product recovered was 2-methyl-2-nitro-1,3-propanol. Total reaction time was about 3/4 of an hour.
EXAMPLE 3
Following the procedure set forth in Example 1, above, 0.1 mole of 1-nitropropane was reacted with 0.2 mole of paraformaldehyde in toluene solvent using t-n-butyl phosphine as the catalyst. The product was 2-nitro-1-butanol. Total reaction time was about 1 hour.
EXAMPLE 4
Following procedure of Example 1, above, 0.1 mole of nitroethane was reacted with 0.2 mole of n-butyraldehyde in tetrahydrofuran solvent using tris-(2-cyanoethyl)phosphine as the catalyst. Recovered product was 2-nitro-3-hexanol. Total reaction time was about 2 hours. | In a process for preparing a nitroalcohol by reacting a nitroparaffin and an aldehyde in a solvent, the improvement comprising the use of 0.5 to 5 mole percent of a trialkyl phosphine, based on the nitroparaffin, which greatly reduces reaction time to 0.1 to 5 hours. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a continuation of U.S. patent application Ser. No. 10/264,458 entitled “NON-SEIZE MATERIAL ATTACHMENT FOR A DRILL SLIP SYSTEM,” filed Oct. 4, 2002, now U.S. Pat. No. 6,758,280, the entire contents of which is incorporated by reference herein, which claims the benefit of U.S. Provisional Application No. 60/327,241, filed Oct. 5, 2001.
FIELD OF THE INVENTION
This invention relates to an improved apparatus and method of preventing cold working of slip assembly components, and more particularly, to an apparatus and method of applying a material to a contact surface of a slip segment or a slip bowl, to prevent cold working between the slip segment and the slip bowl.
BACKGROUND OF THE INVENTION
When drilling for oil or gas, a platform is typically used to support a circular rotary table. Rotational energy is supplied to the rotary table through motors or the like, to move the rotary table in a circular fashion. The rotary table includes a central kelly bushing which provides a central opening or bore through which a drill pipe or a drill string passes. The kelly bushing typically includes four “pin holes” which receive pins on the master bushing that drives the kelly when interlocked with the kelly bushing. The rotary table, kelly, master bushing and kelly bushing are art terms which refer to the various parts of the drilling rig which impart the needed rotational force to the drill string to effect drilling. Such well drilling equipment is known in the art.
When adding or removing a drill pipe from the drill string, wedges, commonly referred to as “slips” are inserted into the rotary table central opening to engage a slip bowl. The slips wedge against the drill pipe to prevent the pipe from falling into the well bore. Often, placement of the slips is manual, and slips or slip assemblies (assemblies of a plurality of slips linked together) usually include handles for gripping and lifting by well personnel, commonly referred to as “roughnecks”. Typically, rigs are equipped with such “hand slips”. When a pipe is disconnected from the drill string, using a power tong or the like, the remaining portion of the drill string can be supported so that additional sections of pipe can be added to/or removed from the drill string.
A more modern and commonly used slip system, called a “power slip”, includes a plurality of slip segments or slip assemblies that are retained within a slip bowl to prohibit the slips from vertical movement while the slip bowl rotates with the rotary table about the drill pipe. The slips and the bowl are configured such that outer surfaces of the slip segments contact inner surfaces of the slip bowl with sliding friction.
A problem commonly experienced by these power slip systems is that the sliding friction between the slips and the bowl tend to cause these parts to stick or seize upon rotation of the bowl about the slip. Since both the slips and the bowl are generally made from steel, the two parts, when loaded together at a combination of high contact pressure and high sliding friction, have a tendency to bond together in a process called cold welding. The more alike the atomic/elemental structures of both the parts are, the higher the probability that the parts will cold weld. Such cold welding can be catastrophic because the seized parts will tend to rotate the drill pipe with the rotary table and make disengagement of a drill pipe from the drill string improbable.
One method commonly used for reducing cold working between the slip and the slip bowl is to lubricate the parts with a lubricant, such as grease. However, this method requires that the parts be lubricated/greased frequently, typically every 20 to 30 cycles, which can be expensive and harmful to the environment.
Accordingly, there is a need for an inexpensive and environmentally safe method of treating the contact surfaces of the slips segments or the slip bowl, such that cold working between the slip segments and the slip bowl is reduced.
SUMMARY OF THE INVENTION
The present invention is directed to an oil or gas well slip system that includes a first movable member having an interactive contact surface and a second movable member having a mating interactive contact surface for slidable engagement with the interactive contact surface of the first movable member. The first and second movable members are each composed of a first material. A second material, compositionally different from the first material, is attached to the interactive contact surface of either the first or the second movable member.
Another embodiment of the invention is directed to a method of reducing cold welding between a first movable member and a second movable member in an oil or gas well slip system. The method includes providing a first movable member having an interactive contact surface and providing a second movable member having a mating interactive contact surface for slidable engagement with the interactive contact surface of the first movable member. The first and second movable members are each composed of a first material. A second material, compositionally different from the first material, is attached to the interactive contact surface of either the first or the second movable member.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic view of a power slip system in accordance with the present invention mounted onto a rotary table;
FIG. 2 is a top view of a slip bowl of the power slip system in FIG. 1 ;
FIG. 3 is a cross-sectional side view of the slip bowl of FIG. 2 , taken in the direction of line 3 — 3 of FIG. 2 ;
FIG. 4 is a top view of a slip assembly of the power slip system in FIG. 1 shown in an “open” position;
FIG. 5 is a cross-sectional side view of the slip assembly of FIG. 4 , taken in the direction of line 5 — 5 of FIG. 4 ; and
FIG. 6 is a top view of a slip assembly of the power slip system in FIG. 1 shown in an “closed” position.
DETAILED DESCRIPTION
FIG. 1 illustrates a conventional rotary table 12 for suspending a drill pipe or a drill string 14 , which is turned about a vertical axis 16 in a well bore. The table includes a power slip system 10 according to the present invention. The power slip system is preferably a Varco BJ® PS 21/30 power slip system. The system includes a slip bowl 20 which is mounted within a central opening 18 of the rotary table, and a slip assembly 22 which is rotatably coupled within the slip bowl. In one embodiment, the slip assembly 22 comprises a plurality of slip segments having tapered outer walls that are adapted to engage tapered inner walls of the bowl to retain the slip assembly 22 from lateral, but not rotational, movement within the bowl. Each slip segment carries along its inner surface an insert which grips the drill string to prevent the drill string from falling into the well bore. A centering device 24 is disposed on top of the bowl to center or align the drill string along the vertical axis. In one embodiment, a material 51 is applied to either the tapered outer walls of the slip segments or the tapered outer walls of the slip bowl to reduce cold working between the slip assembly and the slip bowl during drilling operations.
With reference to FIGS. 2 and 3 , the slip bowl 20 comprises an arc or C-shaped section 30 , which forms a semi-circular partially enclosed annular body. The slip bowl is preferably cast from an alloy or low alloy steel, such as CMS 02 grade 150-135 steel, or more preferably CMS 01 steel, or most preferred, CMS 02 grade 135-125 steel. The section further includes an annular outer surface 36 and an upwardly tapered inner surface 38 . The section is symmetric about a vertical axis 16 to form a central bore 35 for receiving the slip assembly 22 (FIG. 1 ).
Externally, the outer surface 36 of the body section 30 is defined by a cylindrical shoulder 40 that outwardly extends from an upper portion of the section and a complementary, reduced diameter outer cylindrical surface 42 . As shown in FIG. 1 , the complementary outer surface 42 is received and confined within the central opening 18 and the shoulder 40 is received by a recess 17 in the central opening 18 and abuts a rotary table shoulder 15 , such that the slip bowl 20 is effectively supported in the rotary table 12 .
Referring back to FIG. 3 , internally, the tapered inner surface 38 of the slip bowl sections are corrugated to form a plurality of grooves 44 that extend into the central bore 35 . The tapered inner surface 38 and the grooves 44 together define a tapered contact surface 46 of the slip bowl 20 for receiving and engaging the outer surface of the slip assembly 22 . The grooves 44 are configured to allow the slip assembly 22 to recess into the slip bowl 20 such that the slip assembly 22 occupies a smaller amount of the central bore 35 , thus allowing for a larger clearance for the drill string 14 within the slip assembly 22 when the slip assembly 22 is in an “open” position, as defined below.
Referring to FIG. 2 , the partially enclosed annular body section 30 has a pair of hydraulic actuators 48 mounted on opposite sides of the body 30 , which raise the slip assembly 22 between the “open” position and a “closed” position. In the open position, the slip assembly 22 is raised to receive the drill string 14 within the central bore 35 . In the “closed” position, the slip assembly 22 is lowered to grip the drill string 14 within the central bore 35 of the slip bowl 20 . An arc-shaped door 50 is removably coupled between open ends of the body section 30 of the slip bowl 20 to fully enclose the body and form an enclosed annular body that retains the slip assembly 22 .
Referring to FIGS. 4 to 6 , in a preferred embodiment, the slip assembly 22 comprises a generally annular body formed by a center slip segment 60 , a left hand slip segment 62 and a right hand slip segment 64 . However, although three slip segments are shown, the slip assembly 22 may comprise any number of slip segments. The slip segments are symmetrically disposed about the vertical axis 16 ( FIG. 5 ) to form an orifice 66 ( FIG. 6 ) for receiving the drill string. The slip segments are preferably cast from CMS 02 grade 150-135 steel, or more preferably, CMS 01 steel. The left and right hand slip segments 62 and 64 are hinged at opposite ends of the center slip segment 60 by a pair of hinge pins 68 . The free ends of the left and right hand slip segments 62 and 64 are biased away from each other, i.e. towards the “open” position, by use of hinge springs 70 (FIG. 5 ). The slip assembly 22 also includes a handle 72 , which may be coupled to the center slip segment 60 . The handle 72 locks the left and right hand slip segments 62 and 64 into engagement with the actuators 48 (FIG. 2 ), which force the slip segment against the spring bias and to the “closed” position (as shown in FIG. 6 ) or retain the free ends of the left and right slip segments in abutment to form an enclosed annular structure.
Each slip segment has an arcuate body shape defined by a radial interior surface 74 and a downwardly tapered exterior surface 76 . The interior surface 74 of the slip segments are adapted to receive a set of inserts 78 that extend essentially circumferentially about the orifice 66 to grip and support the drill string 14 . The inserts 78 preferably have external teeth for assuring effective gripping engagement with the drill string 14 .
The downwardly tapered exterior surface 76 of each slip segment is corrugated to form a plurality of fingers 80 that outwardly extend from the body of each slip segment and are configured to mate with the slip bowl grooves 44 . The downwardly tapered exterior surface 76 and the fingers 80 together define a tapered contact surface 82 of each slip segment, wherein the tapered contact surface 82 of each slip segment is adapted to engage the inner contact surface 42 of the slip bowl 20 . The fingers 80 engage the slip bowl grooves 44 to retain each slip segment from lateral movement with the slip bowl 20 . Under normal drilling conditions, the slip assembly 22 is required to support lateral loads of about 1 ton to about 750 tons.
Since cold welding between the slip assembly 22 and the slip bowl 20 can be caused by casting the slip segments and the slip bowl 20 from similar steel materials, it is desirable that either the slip segments or the slip bowl 20 is cast from a material that is dissimilar to steel. Such a material should have little or no tendency to dissolve into the atom structure of steel. However, casting the slip segments or the slip bowl from a material other than that of steel requires specialized hardware and is expensive to fabricate. Thus, another solution to prevent cold welding between the slip assembly 22 and the slip bowl 20 is to fabricate the slip segments and the slip bowl 20 from a steel material and to coat or plate either the contact surface 46 of the steel slip bowl 20 ( FIG. 3 ) or the contact surface 82 of the steel slip assembly 22 with the material 51 ( FIG. 5 ) that is dissimilar to steel and has little or no tendency to dissolve into the atom structure of steel. Although, for clarity, the following description describes attaching the material 51 to the contact surface 82 of each slip segment of the slip assembly 22 , the material 51 may alternatively be attached to the contact surface 46 of the slip bowl 20 by any of the methods described below.
The material 51 may comprise any non-steel metallic material, such as Copper (Cu) based materials. For example, in one embodiment the material 51 is a metallic layer of a bronze alloy (NiAlCu) having a composition of approximately 13.5% Al (Aluminum), approximately 4.8% Ni (Nickel), approximately 1.0% Mn (Manganese), approximately 2.0% Fe (Iron) and approximately 78.7% Cu (Copper). In alternative embodiments, the material 51 may comprise Tungsten Carbide, Molybdenum, or any other metal in the nickel, aluminum or bronze family.
The material 51 may be applied or assembled to the tapered contact surfaces 82 of each slip segment by any suitable technique. In a preferred process, the material 51 is applied to each slip segment by MIG (Metal Inert Gas) welding with an argon shield. This may be accomplished by the use of a pulse machine by manual application or automatic or sub-arc welding and extra welder protection, such as a gas exhaust system, may be utilized to protect the welder from the toxic gas developed during welding. An alternative process of cold wire TIG (Tungsten Insert Gas) welding may also be used to apply the material 51 to the tapered contact surfaces 82 of each slip segment.
In one embodiment, before applying the material 51 , the slip segments are pre-heated to a temperature in a range of approximately 250° C. to approximately 400° C. to prevent cracking of the material 51 during cool down. For example, in one embodiment the slip segments may be pre-heated to a temperature of approximately 250° C., and more preferably to a temperature of about 350° C. The material 51 , preferably about ⅛ inches thick, may be welded to the contact surfaces 82 of the slip segments with wire 402 (390-410 HB), or more preferably with a softer wire type 302 (300-320 HB) applying a current of about 150 A to about 350 A and a voltage of about 25V to about 30V.
In an alternative embodiment, the material 51 may be applied by an electric thermal spray, a metal flame spray method or another similar coating method. For example, the slip surfaces 82 may be coated with 400 HB (Brinell Hardness) NiAlCu, which provides a hardness of approximately 43 HRC (Rockwell Hardness C Scale) after application, or more preferably the slip surfaces 82 may be coated with 300 HB NiAlCu, which provides a hardness of approximately 32 HRC after application. After application, the slip segments may be turned on a mandrel and machined to a thickness in a range of approximately ¼ inches to {fraction (1/16)} inches, preferably approximately 0.08 inches (2 mm). In one embodiment, the material is turned until the material hardness is in a range of approximately 35 to about approximately 56 HRC.
During the turning operation, the slip segments acquire a very smooth final machine surface which will require little buffing afterwards. For example in one embodiment, after final turning, the contact surfaces of the slip segment have close to a mirror finish (i.e. close to the same finish as polished steel), such as a surface finish in a range of approximately 8 to approximately 64. During the application process, the material 51 may be added using a common fabrication process. Thus, not only are the initial fabrication costs minimized, but the slips may be easily repaired in conventional facilities.
In one embodiment, the material 51 is mechanically attached to the contact surface 82 of each slip segment, such as by use of screw fasteners or the like.
In any of the above embodiments, one or both of the slip bowl and the slip segment may be carburized to harden the slip bowl or the slip segment material, respectively. Any of the above embodiments may also comprise more than one layer of the material 51 .
As discussed above, although the material 51 has been described as being attached to the contact surface 82 of each slip segment, the material 51 may alternatively be attached to the contact surface 46 of the slip bowl 20 by any of the methods described above.
In accordance with the present invention, sticking between the slip assembly 22 and the slip bowl 20 is minimized. As a result, static friction between slip segments and slip bowl 20 is reduced, enabling the slip assembly 22 to self-release from the slip bowl 20 after an axial load from the drill string 14 to the slip assembly 22 is released. Accordingly, the attachment of the material 51 , being comprised of a material that is different from the material of the slip assembly 22 and the slip bowl 20 , to either the slip assembly 22 or the slip bowl 20 reduces cold welding between the stationary slip assembly 22 and the rotating slip bowl 20 .
The present invention also provides the advantage of non-lubricated or greaseless slips. Thus, the relatively large expense of providing large quantities of lubrication or grease between the slip assembly and the slip bowl to prevent the slip assembly from sticking to the slip bowl during the drilling is replaced by the relatively inexpensive means of the present invention, which is also safe for the environment
It should be understood that the embodiments described and illustrated herein are illustrative only, and are not to be considered as limitations upon the scope of the present invention. Variations and modifications may be made in accordance with the spirit and scope of the present invention. It is understood that the scope of the present invention could similarly encompass other materials that are dissimilar to steel. The method of the present invention may be used to control and repair wear on surfaces of big steel machines and other similar wear components. Therefore, the invention is intended to be defined not by the specific features of the preferred embodiments as disclosed, but by the scope of the following claims. | An oil or gas well slip system is provided that includes a first movable member having an interactive contact surface and a second movable member having a mating interactive contact surface for slidable engagement with the interactive contact surface of the first movable member. The first and second movable members are each comprised of a first material. A second material, compositionally different from the first material, is attached to the interactive contact surface of either the first or the second movable member. | 4 |
FIELD OF THE INVENTION
The present invention relates to the synthesis of silver nanoclusters, and more specifically to the synthesis of silver nanoclusters on the presence of zeolite.
BACKGROUND OF THE INVENTION
Zeolites are very attractive host materials for developing nanocomposites due to their ability to selectively exchange and integrate transition metals, salts, charged and neutral species within their cages and interconnecting channels. Ion exchange research studies in zeolites started in the 1950s' when the formation of superlattices in these systems was reported. Since then, many research advances have been accomplished in the development and study of the properties of various metal ions in zeolite frameworks. Currently, silver zeolite materials have many applications in different areas such as catalysis, biological labeling, medicine, water treatment, antibacterial products, optoelectronics, and surface enhanced Raman scattering.
Aqueous ion exchange and molten salts have been the regular methods to introduce cationic species inside the cages of various types of zeolites. In addition, the physical and chemical properties of the host materials produced by those techniques have been controlled and improved by annealing under inert and reactive atmospheres. Manufacture of high quality silver zeolite implies long reactions times, usually over 20 hours, and a highly trained production workforce along with special facilities to handle high temperatures and very-low- vacuum systems. In order to overcome this technical scenario, a variant of the so-called “polyol” process is applied in which silver nitrate is reduced by ethylene glycol in the presence of a polymer cationic binder. The polyol method has proven to control shape, purity, and size distribution of metallic silver nanostructures. However, what is needed is a simple, cost-effective synthesis method for the production of silver nanoclusters.
SUMMARY OF THE INVENTION
The synthetic procedure of the present invention is carried out in the presence of a zeolite producing silver nanoclusters zeolite
According to an aspect of the invention, a mixture of ethylene glycol and zeolite is prepared; and silver nitrate is then added to said mixture.
According to one aspect of the invention, ethylene oxide could alternatively be mixed with the zeolite.
According to another aspect of the invention, the mixture of ethylene oxide and zeolite is stirred and heated until it reaches 160° C. In accordance to another aspect of the invention, the zeolite comprises sodium aluminosilicate, zeolite powder.
In still another aspect of the invention, silver nitrate is added to said mixture at a molar proportion of about 0.6-1:2 of silver nitrate to zeolite.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying figures showing illustrative embodiments of the invention, in which:
FIG. 1 shows comparative SEM images of untreated smooth zeolite substrates, and Agn-Z samples showing silver nanoclusters according to the present invention.
FIG. 2 shows XPS spectra for untreated zeolite, and Agn-Z sample according to the present invention.
FIG. 3 shows XPS spectra for the Ag 3d 5/2 core electrons according to the present invention.
Throughout the figures, the same reference numbers and characters, unless otherwise stated, are used to denote like elements, components, portions or features of the illustrated embodiments. The subject invention will be described in detail in conjunction with the accompanying figures, in view of the illustrative embodiments.
DETAILED DESCRIPTION OF THE INVENTION
Silver nanoclusters were prepared by reducing silver nitrate (ACS grade) with ethylene glycol (reagent plus 99% pure) in the presence of NaA-zeolite powder (Na 2 [Al 2 SiO 6 ]·nH2O; 99.9%). Other equivalent zeolite structures could be used to produce the same phenomena. Silver nitrate was added to a mixture of ethylene glycol and zeolite that were previously stirred and heated at 160° C. for about 30 minutes or until the desired temperature is reached. A molar proportion of 0.6-1:2 of silver nitrate to zeolite produced immediately a light silvery gray material. The temperature during the reaction was kept at about 160° C. The mixture was then allowed to react for about 15 minutes to assure the reaction was completed and finally was allowed to cool at room temperature. The precipitate was filtered and washed several times with dionized water. Physical and chemical characterizations were determined with a JEOL 5800LV scanning electron microscope (SEM) with low vacuum, and with X-ray fluorescence (EDAX); surface analysis was achieved with a PHI 5600ci X-ray photoelectron (XPS or ESCA).
The Agn-Z samples analyzed were prepared using the above-mentioned molar proportion since it was found that the material's color did not darken with increased reaction time. Morphological analysis of bulk materials shows in FIG. 1 , a SEM image (a) of untreated smooth zeolite substrates, a SEM image (b) of an Agn-Z sample of −1 μm with silver nanoclusters of 100 to 200 nm, and a SEM image (c) of an Agn-Z sample with high concentration of silver nanoclusters. EDAX microanalysis of sample (c) showed a maximum concentration of 38 wt % of silver.
FIG. 2 shows the results of surface analysis, wherein plot (a) illustrates XPS full spectra for an untreated zeolite, and plot (b) illustrates XPS full spectra for an Agn-Z sample with high concentration of silver nanoclusters. Silver atomic concentrations ranged from 3.1 to 5.7%. No traces of nitrogen were measured which could indicate that the silver signal corresponds mostly to silver species. FIG. 3 is a plot showing the spectra for the Ag3d 5/2 core electrons with binding energy at 368.6 eV, which is higher than the binding energy of metallic silver (368.3 eV); this shifting could be attributed to size effects.
Gold-Silver Nanoclusters on Zeolite Substrates
Silver nanoclusters that were synthesized using the technique described herein were fuctionalized with gold nanoparticles by adding drops of a solution 1.0 M of HAuCl 4 to a suspension of silver nanoclusters on zeolites at 160° C. The silvery gray suspension changed its color to a bluish color immediately after adding the HAuCl 4 , indicating the formation of gold nanoparticles that were attracted onto the silver nanoclusters. Silver nanoclusters have potential to enhance Raman scattering for sensing and biodetection applications and the gold nanoparticles could be used as conductive composites and for photo-triggered drug delivery. Gold-silver nanocornposites could serve as building blocks to construct more complex macromolecules and lattices.
Silver Nanoclusters on Zeolite Substrates Films for Photovoltaic Cells
Annealing at 300° C. silver nanoclusters on zeolite substrates prepared by the technique described herein produces blue-green photoluminescence under excitation with UV light. This phenomenon could be used to improve solar cells efficiency and have a great potential for developing photovoltaic cells.
Silver Nanoclusters on Zeolite Substrates for Antibacterial, Antifungal and Antivirus Applications
Silver natural antibacterial, antifungal and antivirus properties have great potential for applications in the health industry. Silver nanoclusters on zeolite substrate could make into air filters for operation rooms at hospital facilities, also a can be used to clean thoroughly surgical areas and equipment to create emergency aseptic environments.
It is proposed that the technique of the present invention could potentially be applied to other transition metals and could be optimized to obtain silver nanodots or other structures.
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims. | Silver nanoclusters were synthesized by reducing silver nitrate with ethylene glycol at a certain temperature in the presence of zeolite. A one-pot procedure rendered uniform size distributions of quasi-spherical silver clusters synthesized on the surfaces of cubic-like zeolite. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to β-amino acid derivatives as dipeptidyl peptidase-IV inhibitors and the processes for the synthesis of the same. This invention also relates to pharmacological compositions containing the compounds of the present invention, and methods of treating diabetes, especially type 2 diabetes, as well as prediabetes, diabetic dyslipidemia, metabolic acidosis, ketosis, satiety disorders, and obesity. These inhibitors can also be used to treat conditions manifested by a variety of metabolic, neurological, anti-inflammatory, and autoimmune disorders like inflammatory disease, multiple sclerosis, rheumatoid arthritis; viral, cancer and gastrointestinal disorders. The compounds of this invention can also be used for treatment of infertility arising due to polycystic ovary syndrome.
BACKGROUND OF THE INVENTION
[0002] Type 2 diabetes mellitus, also known as “non-insulin dependent diabetes mellitus” (NIDDM), afflicts an estimated 6% of the adult population in western society and is expected to grow at a rate of 6% per annum worldwide. Type 2 diabetes is a complex metabolic disorder, characterized by hyperglycemia and hyperinsulinemia. This results from contribution of impaired insulin secretion from β-cells in pancreas and insulin resistance, mainly, in muscle and liver. The insulin resistant individuals, in addition to being hyperglycemic, exhibit a constellation of closely related clinical indications, which include obesity, hypertension and dyslipidemia. The uncontrolled hyperglycemia can further lead to late-stage microvascular and macrovascular complications such as nephropathy, neuropathy, retinopathy and premature atherosclerosis. In fact, 80% of diabetic mortality arises from atherosclerotic cardiovascular disease (ASCVD).
[0003] Presently, several pharmacological agents are available as antihyperglycaemic agents to mitigate the conditions manifested in NIDDM ( Lancet , (2005) 365, 1333-1346). These include (1) insulin secretagogues, which increase insulin secretion from pancreatic cells [e.g., sulphonyl ureas (glimeperide) and non-sulphonyl ureas (repaglinide)], (2) biguanides, which lower hepatic glucose production, e.g., metforminutes, and (3) α-glucosidase inhibitors, which delay intestinal absorption of carbohydrates, e.g., acarbose ( Lancet , (2005) 365, 1333-1346). The insulin sensitizers like pioglitazone and rosiglitazone (TZDs), which exhibit their effect by PPARγ agonism, control hyperglycaemia by improving peripheral insulin sensitivity without increasing circulating insulin levels. However, all these agents are associated with one or more of side effects like hypoglycaemia, gastrointestinal side effects including abdominal discomfort, bloating, flatulence, hepatotoxicity, weight gain, dilutional anemia and peripheral edema ( Endocrine Rev ., (2000) 21, 585-618).
[0004] Given its prevalence and complexity of NIDDM, there is a growing need for novel strategies and effective therapeutic approaches for treatment of diabetes. The safe and, preferably, orally bioavailable therapeutic agents, that would accelerate glucose clearance by stimulating endogenous insulin secretion in a glucose-dependent manner without hypoglycemic episodes and previously mentioned side effects, would represent an important advance in the treatment of this disease.
[0005] One such novel approach appearing on the horizon involves enhancing the levels of incretin (insulin-secreting) hormones, glucagon-like peptide-1 (GLP-1) and glucose-dependent insulinotropic polypeptide (GIP) ( Expert Opin. Investig. Drug , (2005) 14, 57-64). These hormones mediate the process of insulin release from pancreatic β-cells in a glucose-dependent manner. GLP-1 (7-36) is a polypeptide of 29 amino acids derived by post translational processing of proglucagon in the L-cells of the distal small intestine in response to the food intake. It has multiple synergistic antidiabetic actions including stimulation of insulin secretion, inhibition of glucagon, inducement of feeling fullness and delayed gastric emptying. Administration (continuous infusion) of exogenous GLP-1 in diabetic patients has been demonstrated to be efficacious in lowering blood glucose levels by enhancing glucose-mediated insulin secretion, suppressing glucagon secretion and slowing gastric emptying. Additionally, preclinical studies with GLP-1 or Exendin-4 in streptozotocin-injected neonatal rats have implicated the role of GLP-1 in neogenesis and preservation of β-cells ( Current Opin. Pharma ., (2004) 4, 589-596 ; Expert Opin. Investig. Drug, 2003, 12, 87-100).
[0006] However, these incretin hormones are very short lived (t1/2 GLP-1=˜2 minutes, t1/2 GIP=˜7 min) because they are very rapidly cleaved by the enzyme dipeptidyl peptidase-IV (DPP IV, CD26, EC 3.4.14.5) to GLP-1 (9-36) and GIP (3-42), which are the weak antagonists of GLP-1 and GIP receptors respectively ( Reg. Peptides , (2005) 128, 125-134). DPP IV is a serine protease known for cleavage of polypeptides with specificity for Pro/Ala at the penultimate position from the N-terminus. It is expressed on the surface of epithelial cells of intestine, liver, kidney proximal tubules, prostrate, corpus luteum, lymphocytes and macrophages. It is now proven that DPP IV inhibition leads to an increase of biologically active forms of both GLP-1 and GIP to therapeutically beneficial levels and thus enhances the body's own normal homeostatic mechanism. As the incretins are released by the body, only in response to the food intake, DPP IV inhibition is not expected to increase the level of insulin at inappropriate times, such as in between meals, which can otherwise lead to hypoglycemia. The initial proof of concept for DPP IV based therapy has been obtained from DPP IV knockout (KO) mice and other preclinical animal models. The DPP IV KO rat and mice have shown normal glucose tolerance and didn't develop diabetic symptoms, even when fed with fat-rich food. Clinical and pre-clinical studies with DPP IV-resistant GLP-1 analogs like Exenatide have provided indirect but valuable additional validation for the DPP IV target. In clinical trials with an early DPP IV inhibitor, viz., NVP DPP 728, significant improvement in mean 24 h glucose excursion with lower insulin, glucagon and HbAlc levels were observed in the treated patients. Experimental evidence suggests that DPP IV inhibition offers an added benefit in preservation and regeneration of 0 cells. DPP IV inhibitors may thus be used in disease modifying therapy in type 1 and late-stage type 2 diabetes.
[0007] GLP-1 has been proposed to be one of the physiological regulators of appetite and food intake. The DPP IV inhibitors may also manifest the beneficial effect of delaying gastric emptying observed with GLP-1. This is further corroborated by recent Phase II studies that no body weight gain was observed with DPP IV inhibitors during the treatment period of the patients with diabetes and obesity ( Current Opin. Pharma ., (2004) 4, 589-596).
[0008] The present invention provides DPP IV inhibitors and methods for treating conditions mediated by DPP IV like diabetes, especially, type 2 diabetes mellitus, as well as prediabetes, diabetic dyslipidemia, metabolic acidosis, ketosis, satiety disorders, and obesity. These inhibitors can also be used to treat conditions manifested by a variety of metabolic ( Expert Opin. Investig. Drug , (2003) 12, 87-100), neurological ( Brain Res ., (2005) 1048, 177-184), anti-inflammatory, and autoimmune disorders ( Clin. Diagnostic Lab. Immunol . (2002) 9, 1253-1259) like inflammatory disease, multiple sclerosis, rheumatoid arthritis ( Clin. Immunol. Immunopath ., (1996) 80, 31-37); viral ( Clin. Immunol ., (1999) 91, 283-295), cancer ( Cancer Res ., (2005) 65, 1325-1334), blood disorders ( Blood , (2003) 102, 1641-1648) and gastrointestinal disorders. The compounds of this invention can also be used for treatment of infertility arising due to polycystic ovary syndrome.
[0009] WO 04/009544 discloses 2-cyano-4-fluoropyrrolidine derivatives or their salts. WO 03/106456 discloses compounds allegedly possessing dipeptidyl peptidase-IV enzyme inhibitory activity. WO 03/074500 discloses compounds which contain fluorine atoms and are said to be DPP IV enzyme inhibitors. WO 03/02553 discloses fluoropyrrolidines described as dipeptidyl peptidase inhibitors. WO 03/037327 discloses N-(substituted)pyrrolidine derivatives described as dipeptidyl peptidase-IV inhibitors. WO 03/057666 discloses inhibitors of dipeptidyl peptidase-IV. WO 01/055105 discloses N-(substituted)-2-cyanopyroles and pyrrolines, which are the inhibitors of the enzyme DPP IV. U.S. Pat. No. 6,011,155 discloses N-(substituted glycyl)-2-cyanopyrrolidines, pharmaceutical compositions containing them and their use in inhibiting dipeptidyl peptidase-IV. The compound (2S)-1-[[(3-hydroxy-1-adamantyl)amino]acetyl]-2-cyanopyrrolidine [vildagliptin] has been disclosed as a potent, selective, and orally bioavailable dipeptidyl peptidase-IV inhibitor with antihyperglycemic properties vide reference J. Med. Chem., (2003) 46(13), 2774-2789
[0010] WO 03/000181, WO 03/004498, WO 03/082817, WO 04/007468, WO 04/0167133, WO 04/032836, WO 04/037169, WO 04/058266, WO 04/064778, and WO 04/069162 disclose diverse β-amino acid based phenylbutanamide derivatives described as DPP IV inhibitors. WO 04/083212, WO 04/085661, WO 04/087650 and WO 04/085378 disclose the processes for the preparation of enantiomerically enriched beta amino acid derivatives said to be useful for the asymmetric synthesis of biological active molecules. WO 98/17273 discloses use of butyric acid derivatives said to protect against hair loss or damage in human cancer patients undergoing chemo- or radiation therapy. WO 96/26183 discloses 1-aryl-2-aylamino-ethane compounds and their use as neurokinin 1-antagonist. U.S. Pat. No. 5,665,876 discloses 3-(aminoacyl-amino) saccharides, which have been said to clarify the biological function of glycoproteins. WO 05/040095 and WO 05/056003 disclose compounds described as having dipeptidyl peptidase-IV inhibitory activity. The patent applications WO 01/055105, WO 03/000180, WO 05/056103, WO 04/050022, WO 04/043490, WO 04/089362, WO 04/103276, and WO 05/095343 describe the β-amino acid based derivatives as the inhibitors of DPP IV.
SUMMARY OF THE INVENTION
[0011] The present invention provides compounds containing β-amino acid derivatives possessing dipeptidyl peptidase-IV enzyme inhibitory activity. Also provided are processes for synthesizing such compounds.
[0012] These compounds can be used in treatment of conditions mediated by DPP IV, such as diabetes, especially, type 2 diabetes mellitus as well as pre-diabetes, diabetic dyslipidemia, metabolic acidosis, ketosis, satiety disorders, and obesity. These inhibitors can also be used for treating conditions manifested by a variety of metabolic, neurological, anti-inflammatory, and autoimmune disorders like inflammatory disease, multiple sclerosis, rheumatoid arthritis viral, cancer and gastrointestinal disorders. The compounds of this invention can also be used for treatment of infertility arising due to polycystic ovary syndrome.
[0013] Pharmaceutical compositions containing such compounds are provided together with the pharmaceutically acceptable carriers or diluents, which can be used for the treatment of dipeptidyl peptidase-IV mediated pathologies. These pharmaceutical compositions may be administered or coadministered by a wide variety of routes, for example, oral or parenteral. The composition may also be administered or coadministered in slow release dosage forms.
[0014] Although, one specific enantiomer has been shown by way of example, the racemates, diastereomers, N-oxides, polymorphs, pharmaceutically acceptable salts and pharmaceutically acceptable solvates of these compounds, prodrugs and metabolites, having the same type of activity, are also provided as well as pharmaceutical compositions comprising the compounds, their metabolites, racemates, enantiomers, N-oxides, polymorphs, solvates, prodrugs or pharmaceutically acceptable salts thereof, in combination with a pharmaceutically acceptable carrier and optionally included excipients.
[0015] Other objects will be set forth in accompanying description and in the part will be apparent from the description or may be learnt by the practice of the invention.
[0016] In accordance with one aspect of the invention, are provided compounds having the structure of formula I
[0000]
[0000] including pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers, polymorphs, prodrugs, metabolites or N-oxides thereof,
wherein
A is selected from aryl or heteroaryl group.
E and E′ are independently —(CR a R b ) 1 — (wherein 1 is an integer of 1 to 2 and R a and R b are independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl or heterocyclyl; R a and R b can together form a ring, which can be optionally unsaturated); and
R can be selected from the groups a to c:
[0000]
[0000] wherein
R c is hydrogen or alkyl;
R d is hydrogen, alkyl, aryl, heteroaryl, heterocyclyl or cycloalkyl;
R e is hydrogen, alkyl, halogen, cyano, carboxy, hydroxyl, alkoxy, carbonyl or amino;
a and b are an integer of 0-2;
J is a bond, —O—, —NR f —, —NR f CO—, —NR f CONR f —, —NR f SO 2 —, —NR f C(O)O—, or —OCONR f —, wherein R f refers to hydrogen, alkyl, cycloalkyl, aryl, heteroaryl or heterocyclyl;
J 1 is hydrogen, alkyl, cycloalkyl, aryl, heteroaryl or heterocyclyl (when J is —NR f SO 2 —, or NR f C(O)O—, then J 1 is not hydrogen);
L is (CH 2 ) p wherein p is an integer of 1-2;
M is CH or N;
[0017] Q is (CH 2 ) q , O or S(O) q wherein q is an integer of 0-2;
R 1 is —(CR a R b ) m — wherein m is an integer of 0-1;
R 2 is —NR f —, —O—, —CO—, —CS—, —CONR f —, —NR f CO—, —NR f CONR f —, —NR f SO 2 —, —NR f COO—, or
—OCONR f —; wherein R f is defined as above;
R 3 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl or heterocyclyl;
R 7 is no atom, —CO—, —CS—, and —SO 2 —;
R 8 is no atom, —O— or —NR f —; and
R 9 is alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl or heterocyclyl, with the following provisos:
(i) when A, E, and E′ are defined as earlier, R as a-1 and a-2 (group a), R 1 as —(CR a R b ) m -{wherein m=0 or m=1 when a=b=1}, and R 2 as —NR f —, then R 3 cannot be a heteroaryl,
(ii) when A, E, and E′ are defined as earlier, R as a-1 (group a) {wherein a is an integer of 0 and b is an integer of 1}, R 1 as —(CR a R b ) m -{wherein m is an integer of 0}, and R 3 as defined earlier, then R 2 cannot be —CONR f .
(iii) when A, E, and E′ are defined as earlier, R as a-1 (group a) wherein a is an integer of 0 and b is an integer of 0-2, R 2 as —O— and —NR f — and R 3 as defined earlier, then R 1 cannot be —(CR a R b ) m — [wherein m is an integer of 1].
(iv) when A, E, and E′ are defined as earlier, R as b-1 (when M is N) and b-2 (group b) or a-4 (group a) wherein R 7 and R 8 are no atom, then R 9 cannot be a heteroaryl,
(v) when A, E, and E′ are defined as earlier, R as a-4 (group a), b-1 (when M is N), b-2, and b-3, (group b), and R 7 as no atom, then R 8 cannot be —O— or —NR f —.
[0018] In yet other embodiment, compounds are provided that include, for example,
Compound No. 1: (3R)-3-Amino-N-[1-(morpholin-4-ylcarbonyl)piperidin-4-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt, Compound No. 2: (3R)-3-Amino-N-{1-[(4-fluorophenyl)sulphonyl]piperidin-4-yl}-4-(2,4,5-trifluorophenyl)butanamide and its 4-methylbenzenesulfonic acid salt, Compound No. 3: (3R)-3-Amino-N-[1-(4-fluorobenzoyl)piperidin-4-yl]-4-(2,4,5-trifluoro phenyl)butanamide and its 4-methylbenzenesulfonic acid salt, Compound No. 4: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-fluorobenzamide and its trifluoroacetic acid salt, Compound No. 5: (3R)-3-Amino-N-[1-(methylsulphonyl)piperidin-4-yl]-4-(2,4,5-trifluoro phenyl)butanamide and its 4-methylbenzenesulfonic acid salt, Compound No. 6: (3R)-3-Amino-N-(3-hydroxy-1-adamantyl)-4-(2,4,5-trifluorophenyl) butanamide and its 4-methylbenzenesulfonic acid salt, Compound No. 7: 4-{[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]amino}-N-(4-chloro phenyl)piperidine-1-carboxamide and its hydrochloride salt, Compound No. 8: (3R)-3-Amino-N-[(1R,5S)-3-(2-thienylsulphonyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt, Compound No. 9: (3R)-3-Amino-N-[(1R,5S)-3-(4-cyanobenzoyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt, Compound No. 10: (3R)-3-Amino-N-[(1R,5S)-3-(2,6-difluorobenzoyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt, Compound No. 11: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-fluorobenzenesulfonamide and its trifluoroacetic acid salt, Compound No. 12: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}morpholine-4-carboxamide and its trifluoroacetic acid salt, Compound No. 13: 1-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-3-(4-chlorophenyl)urea and its trifluoroacetic acid salt, Compound No. 14: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-3-fluoro-4-methoxybenzamide and its trifluoroacetic acid salt, Compound No. 15: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-2-propanesulfonamide and its trifluoroacetic acid salt, Compound No. 16: (3R)-3-Amino-N-[(1R,5S)-3-(4-trifluorobenzenesulphonyl)-3-azabicyclo [3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt, Compound No. 17: (3R)-3-Amino-N-[(1R,5S)-3-(thiophene-2-carbonyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt, Compound No. 18: (3R)-3-Amino-N-[(1R,5S)-3-(ethanesulphonyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt, Compound No. 19: (3R)-3-Amino-N-[(1R,5S)-3-(4-methylbenznesulphonyl)-3-azabicyclo[3.1.0] hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt, Compound No. 20: 4-[({(3R)-1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]pyrrolidin-3-yl}oxy)methyl]benzonitrile and its trifluoroacetic acid salt, Compound No. 21: (2R)-4-{(3S)-3-[(4-Fluorobenzyl)oxy]pyrrolidin-1-yl}-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 22: 4-[({(3S)-1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]pyrrolidin-3-yl}oxy)methyl]benzonitrile and its trifluoroacetic acid salt, Compound No. 23: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-2,2,2-trifluoroethanesulfonamide and its trifluoroacetic acid salt, Compound No. 24: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-cyanobenzenesulfonamide and its trifluoroacetic acid salt, Compound No. 25: N-{1-[3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-2,4-difluorobenzenesulfonamide and its trifluoroacetic acid salt, Compound No. 26: Methyl 5-[({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)sulfonyl]-4-methylthiophene-2-carboxylate, Compound No. 27: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-1,3,5-trimethyl-1H-pyrazole-4-sulfonamide, Compound No. 28: methyl 4-[({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)sulfonyl]-2,5-dimethyl-3-furoate, Compound No. 29: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-fluorobenzenesulfonamide, Compound No. 30: 4-acetyl-N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl] piperidin-4-yl}benzenesulfonamide and its trifluoroacetic acid salt, Compound No. 31: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-2,4-difluorobenzenesulfonamide and its trifluoroacetic acid salt, Compound No. 32: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} methane sulfonamide and its trifluoroacetic acid salt, Compound No. 33: methyl 5-[({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl] piperidin-4-yl} amino) sulfonyl]-4-methylthiophene-2-carboxylate and its trifluoroacetic acid salt, Compound No. 34: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} propane-2-sulfonamide and its trifluoroacetic acid salt, Compound No. 35: N-{(3S)-1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-3-yl}ethane sulfonamide and its trifluoroacetic acid salt, Compound No. 36: 4-(1,3-dihydro-2H-isoindol-2-yl)-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 37: N-{1-[3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}propanamide and its trifluoroacetic acid salt, Compound No. 38: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}acetamide and its trifluoroacetic acid salt, Compound No. 39: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-fluorobenzamide, Compound No. 40: 2-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)-4,6-difluorobenzonitrile and its trifluoroacetic acid salt, Compound No. 41: 2-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)benzonitrile and its trifluoroacetic acid salt, Compound No. 42: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)-2,6-difluorobenzonitrile and its 4-methylbenzenesulfonic acid salt, Compound No. 43: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)-2,6-difluorobenzonitrile and its trifluoroacetic acid salt, Compound No. 44: 2-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)benzonitrile and its trifluoroacetic acid salt, Compound No. 45: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)benzonitrile and its trifluoroacetic acid salt, Compound No. 46: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)benzonitrile and its trifluoroacetic acid salt, Compound No. 47: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)-2-(trifluoromethyl)benzonitrile and its trifluoroacetic acid salt, Compound No. 48: Ethyl ({(3S)-1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]pyrrolidin-3-yl}oxy)acetate and its trifluoroacetic acid salt, Compound No. 49: (2R)-4-oxo-4-[5-(2-thienylacetyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 50: (2R)-4-oxo-4-[5-(trifluoroacetyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine and its hydrochloride salt, Compound No. 51: (2R)-4-oxo-4-(5-propionyl-2,5-diazabicyclo[2.2.1]hept-2-yl)-1-(2,4,5-trifluoro phenyl) butan-2-amine and its hydrochloride salt, Compound No. 52: 5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-cyanophenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its 4-methylbenzenesulfonic acid salt, Compound No. 53: (2R)-4-(5-acetyl-2,5-diazabicyclo[2.2.1]hept-2-yl)-4-oxo-1-(2,4,5-trifluoro-phenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 54: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-fluoro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 55: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-methoxy-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 56: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[4-(trifluoro-methyl)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 57: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-benzyl-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 58: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-methyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 59: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-tert-butyl-2,5-diaza-bicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 60: (2R)-4-{5-[(3-fluorophenyl)sulfonyl]-2,5-diazabicyclo[2.2.1]hept-2-yl}-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 61: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-fluoro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 62: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[2-(trifluoromethyl)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 63: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-methyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 64: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-nitro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 65: 4-{(1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diaza-bicyclo[2.2.1]hept-2-yl}-2-chlorobenzonitrile and its trifluoroacetic acid salt, Compound No. 66: 2-{(1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diaza-bicyclo[2.2.1]hept-2-yl}-6-fluorobenzonitrile and its trifluoroacetic acid salt, Compound No. 67: 4-{(1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diaza-bicyclo[2.2.1]hept-2-yl}-3-fluorobenzonitrile and its trifluoroacetic acid salt, Compound No. 68: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-cyclohexyl-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 69: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-methoxy-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 70: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl) butanoyl]-N-(2-fluoro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 71: (2R)-4-[5-(ethylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 72: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,4-dimethoxyphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 73: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-isopropyl-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 74: 4-{5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo-[2.2.1]hept-2-yl}-2-(trifluoromethyl)benzonitrile and its trifluoroacetic acid salt, Compound No. 75: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[4-(benzyl-oxy)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 76: (2R)-4-[5-(4-fluorobenzoyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 77: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3,4,5-tri-methoxyphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 78: 5-[3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-fluorophenyl)-2,5-diaza-bicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 79: (1S,4S)-5-[3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,6-diisopropyl phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 80: methyl 2-[({(1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diaza-bicyclo[2.2.1]hept-2-yl}carbonyl)amino]benzoate and its trifluoroacetic acid salt, Compound No. 81: (2R)-4-oxo-4-[5-(2-thienylsulfonyl)-2,5-diaza-bicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 82: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(5-chloro-2-methoxy phenyl)-2,5-diazabicyclo [2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 83: 4-({5-[(3R)-3-amino-4-(2,4,5-trifluoro phenyl)butanoyl]-2,5-diazabicyclo [2.2.1]hept-2-yl}sulfonyl)benzonitrile and its trifluoroacetic acid salt, Compound No. 84: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,3-dichlorophenyl)-2,5-diazabicyclo [2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 85: (2R)-4-{(1S,4S)-5-[(3,5-difluorophenyl) sulfonyl]-2,5-diazabicyclo [2.2.1]hept-2-yl}-4-oxo-1-(2,4,5-trifluorophenyl) butan-2-amine and its trifluoroacetic acid salt, Compound No. 86: (1S,4S)—N-(4-acetylphenyl)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl) butanoyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 87: methyl 5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo [2.2.1]heptane-2-carboxylate and its trifluoroacetic acid salt, Compound No. 88: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,5-dimethoxyphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 89: ethyl 5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo [2.2.1]heptane-2-carboxylate and its trifluoroacetic acid salt, Compound No. 90: (2R)-4-oxo-4-[5-(propylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluoro-phenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 91: (2R)-4-[5-(isopropylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluoro phenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 92: (2R)-4-[5-(butylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluoro-phenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 93: (2R)-4-oxo-4-[5-(phenylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 94: (2R)-4-[5-(morpholin-4-ylcarbonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 95: (2R)-4-oxo-4-(5-{[3-(trifluoromethoxy)phenyl]sulfonyl}-2,5-diazabicyclo [2.2.1]hept-2-yl)-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 96: (2R)-4-[5-(methylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 97: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,6-difluoro-phenyl)-2,5-diazabicyclo [2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 98: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,4,6-trifluoro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 99: (1S,4S)—N-(3-acetylphenyl)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl) butanoyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 100: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,5-dichloro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 101: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-isopropyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 102: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-butyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 103: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-ethoxy-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 104: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-ethyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 105: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-isopropyl-6-methylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 106: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-mesityl-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 107: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-methoxy-2-methylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 108: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-phenoxy-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 109: (2R)-4-[(1R,4R)-5-(cyclohexylcarbonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl) butan-2-amine and its trifluoroacetic acid salt, Compound No. 110: (2R)-4-[(1R,4R)-5-(cyclopropyl carbonyl)-2,5-diazabicyclo [2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl) butan-2-amine and its trifluoroacetic acid salt, Compound No. 111: (2R)-4-[(1R,4R)-5-(3,5-difluorobenzyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt, Compound No. 112: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-ethoxyphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 113: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-ethylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 114: methyl 3-[({(1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo[2.2.1]hept-2-yl}carbonyl)amino]benzoate and its trifluoroacetic acid salt, Compound No. 115: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-ethylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 116: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-chloro-4-methylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 117: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[3-(methylthio)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 118: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,4-difluorophenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 119: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,4-dimethylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 120: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3,4-dichlorophenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 121: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[4-chloro-3-(trifluoromethyl)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 122: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-cyanophenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, Compound No. 123: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-isopropylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt, and Compound No. 124: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[3,5-bis(trifluoromethyl)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt.
[0143] In yet another embodiment, the present invention relates to the therapeutically effective dose of a compound of formula I in combination with one or more of other therapeutic agents used for treating metabolic disorders. The examples of such therapeutic agents include, but not limited to,
1) antihyperglycaemic agents: (a) insulin sensitizers, (i) PPAR agonists, for example, PPARγ agonists (e.g., rosiglitazone and pioglitazone), PPARα/γ dual agonists (e.g., tesaglitazar and muraglitazar), PPARγ agonist (e.g., ciprofibrate and fenobibrate) and PPAR pan-agonists (e.g., GSK 667954) (b) biguanides, e.g., metforminutes, (c) insulin secretagogues, for example, sulphonyl ureas (e.g., glimeperide) and non-sulphonyl ureas (e.g., repaglinide), (d) α-glucosidase inhibitors, e.g., acarbose, (e) protein tyrosine phosphatase-1B inhibitors, (f) glucokinase activators, e.g. PSN105 (g) inhibitors of 11β-hydroxysteroid dehydrogenase type 1, (h) glucagon receptor antagonists, (i) GLP-1 and GLP-1 receptor agonists, e.g. Exenatide (j) insulin or insulin mimetics, (k) GIP and GIP receptor agonists (l) PACAP and PACAP receptor agonists; 2) lipid modulating agents, (i) HMG-CoA reductase inhibitors, e.g., atorvastatin, simvastatin, and fluvastatin. (ii) sequestrants (cholestyramine, colestipol, and dialkylaminoalkyl derivatives of a cross-linked dextran) (iii) nicotinyl alcohol, nicotinic acid or a salt thereof, (iv) inhibitors of cholesterol absorption, e.g., β-sitosterol and ezetimibe, (v) acyl CoA:cholesterol acyltransferase inhibitors, e.g., avasimibe (vi) ileal bile acid transporter inhibitors, and (vii) CETP inhibitors, e.g., torcetrapib; 3) antiobesity compounds, (i) CB1 receptor inverse agonists and antagonists, e.g., rimonabant (ii) β3 adrenergic receptor agonists, (iii) melanocortin-receptor agonists, in particular, melanocortin-4 receptor agonists, (iv) ghrelin antagonists, (v) neuropeptide Y1 or Y5 antagonists, (vi) melanin-concentrating hormone (MCH) receptor antagonists and (vii) fenfluramine, dexfenfluramine, phentermine, sibutramine, and orlistat. 4) antihypertensive agents, (i) ACE inhibitors, e.g., enalapril, lisinopril, and quinapril, (ii) angiotensin II receptor antagonists, e.g., losartan, candesartan, irbesartan, valsartan, and eprosartan, (iii) β-blockers, and (iv) calcium channel blockers; and 5) anti-TNF agent or c-AMP raising agent like PDE inhibitors.
[0149] The following terms, used in the specification and claims, shall have the following meanings for the purpose of this application.
[0150] The term “alkyl,” unless otherwise specified, refers to a monoradical branched or unbranched saturated hydrocarbon chain having from 1 to 20 carbon atoms. Alkyl groups can be optionally interrupted by atom(s) or group(s) independently selected from oxygen, sulfur, a phenylene, sulphinyl, sulphonyl group or —NR α —, wherein R α , can be hydrogen, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, aryl, acyl, aralkyl, —C(═O)OR λ , SO m R ψ or —C(═O)NR λ )R π . This term can be exemplified by groups such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, sec-butyl, t-butyl, n-pentyl, isopentyl, neopentyl, n-hexyl, n-decyl, tetradecyl, and the like. Alkyl groups may be substituted further with one or more substituents selected from alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, oxo, thiocarbonyl, carboxy, carboxyalkyl, aryl, heterocyclyl, heteroaryl, (heterocyclyl)alkyl, cycloalkoxy, —CH═N—O(C 1-6 alkyl), —CH═N—NH(C 1-6 alkyl), —CH═N—NH(C 1-6 alkyl)-C 1-6 alkyl, arylthio, thiol, alkylthio, aryloxy, nitro, aminosulfonyl, aminocarbonylamino, —NHC(═O)R λ ), —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ )R π , —C(═O)heteroaryl, C(═O)heterocyclyl, —O—C(═O)NR λ )R π {wherein R λ and R π are independently selected from hydrogen, halogen, hydroxy, alkyl, alkenyl, alkynyl, alkenyl, alkoxy, cycloalkyl, cycloalkenyl, aryl, aralkyl, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or carboxy}, nitro or —SO m R ψ {wherein m is an integer from 0-2 and R ψ is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heterocyclyl, heteroaryl, heteroarylalkyl or heterocyclylalkyl). Unless otherwise constrained by the definition, alkyl substituents may be further substituted by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, —NR λ R π , —C(═O)NR λ )R π , —OC(═O)NR λ R π , —NHC(═O)NR λ R π , hydroxy, alkoxy, halogen, CF 3 , cyano, and —SO m R ψ ; or an alkyl group also may be interrupted by 1-5 atoms of groups independently selected from oxygen, sulfur or —NR α — (wherein R α , R λ , R π , m and R ψ , are the same as defined earlier). Unless otherwise constrained by the definition, all substituents may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, carboxyalkyl, —NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π , hydroxy, alkoxy, halogen, CF 3 , cyano, and —SO m R ψ (wherein R λ , R π , m and R ψ , are the same as defined earlier); or an alkyl group as defined above that has both substituents as defined above and is also interrupted by 1-5 atoms or groups as defined above.
[0151] The term “alkenyl,” unless otherwise specified, refers to a monoradical of a branched or unbranched unsaturated hydrocarbon group having from 2 to 20 carbon atoms with cis, trans or geminal geometry. Alkenyl groups can be optionally interrupted by atom(s) or group(s) independently chosen from oxygen, sulfur, phenylene, sulphinyl, sulphonyl and —NR α — (wherein R α is the same as defined earlier). In the event that alkenyl is attached to a heteroatom, the double bond cannot be alpha to the heteroatom. Alkenyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, —NHC(═O)R λ ), —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —O—C(═O)NR λ R π , alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, keto, carboxyalkyl, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, heterocyclyl, heteroaryl, heterocyclyl alkyl, heteroaryl alkyl, aminosulfonyl, aminocarbonylamino, alkoxyamino, hydroxyamino, alkoxyamino, nitro or SO m R ψ (wherein R λ , R π , m and R ψ are as defined earlier). Unless otherwise constrained by the definition, alkenyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, hydroxy, alkoxy, halogen, —CF 3 , cyano, —NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π and —SO m R ψ (wherein R λ , R π , m and R ψ are as defined earlier). Groups, such as ethenyl or vinyl (CH═CH 2 ), 1-propylene or allyl (—CH 2 CH═CH 2 ), iso-propylene (—C(CH 3 )═CH 2 ), bicyclo[2.2.1]heptene, and the like, exemplify this term.
[0152] The term “alkynyl,” unless otherwise specified, refers to a monoradical of an unsaturated hydrocarbon, having from 2 to 20 carbon atoms. Alkynyl groups can be optionally interrupted by atom(s) or group(s) independently chosen from oxygen, sulfur, phenylene, sulphinyl, sulphonyl and —NR α — (wherein R α is the same as defined earlier). In the event that alkynyl groups are attached to a heteroatom, the triple bond cannot be alpha to the heteroatom. Alkynyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, oxo, thiocarbonyl, carboxy, carboxyalkyl, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, aminosulfonyl, aminocarbonylamino, hydroxyamino, alkoxyamino, nitro, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, —NHC(═O)R λ , —NR λ R π , —NHC(═O)NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π , or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier). Unless otherwise constrained by the definition, alkynyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, carboxyalkyl, hydroxy, alkoxy, halogen, CF 3 , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —C(═O)NR λ R π , cyano or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier).
[0153] The term “cycloalkyl,” unless otherwise specified, refers to cyclic alkyl groups of from 3 to 20 carbon atoms having a single cyclic ring or multiple condensed rings, which may optionally contain one or more olefinic bonds, unless otherwise constrained by the definition. Such cycloalkyl groups can include, for example, single ring structures, including cyclopropyl, cyclobutyl, cyclooctyl, cyclopentenyl, and the like or multiple ring structures, including adamantanyl, and bicyclo [2.2.1]heptane or cyclic alkyl groups to which is fused an aryl group, for example, indane, and the like. Spiro and fused ring structures can also be included. Cycloalkyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, carboxyalkyl, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, aminosulfonyl, aminocarbonylamino, —NR λ R π , —NHC(═O)NR λ R π , —NHC(═O)R λ , —C(═O)NR λ R π , —O—C(═O)NR λ R π , nitro, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or SO m R ψ (wherein R λ R π , m and R ψ are the same as defined earlier). Unless otherwise constrained by the definition, cycloalkyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, hydroxy, alkoxy, halogen, CF 3 , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —OC(═O)NR λ R π , cyano or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier). “Cycloalkylalkyl” refers to alkyl-cycloalkyl group linked through alkyl portion, wherein the alkyl and cycloalkyl are the same as defined earlier.
[0154] The term “aryl,” unless otherwise specified, refers to aromatic system having 6 to 14 carbon atoms, wherein the ring system can be mono-, bi- or tricyclic and are carbocyclic aromatic groups. For example, aryl groups include, but are not limited to, phenyl, biphenyl, anthryl or naphthyl ring and the like, optionally substituted with 1 to 3 substituents selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, alkoxy, acyl, aryloxy, CF 3 , cyano, nitro, COOR ψ , NHC(═O)R λ ), —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —O—C(═O)NR λ R π , —SO m R ψ , carboxy, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or amino carbonyl amino, mercapto, haloalkyl, optionally substituted aryl, optionally substituted heterocyclylalkyl, thioalkyl, —CONHR π , —OCOR π , —COR π , —NHSO 2 R π or —SO 2 NHR π (wherein R λ ), R π , m and R ψ are the same as defined earlier). Aryl groups optionally may be fused with a cycloalkyl group, wherein the cycloalkyl group may optionally contain heteroatoms selected from O, N or S. Groups such as phenyl, naphthyl, anthryl, biphenyl, and the like exemplify this term.
[0155] The term “heteroaryl,” unless otherwise specified, refers to an aromatic ring structure containing 5 or 6 ring atoms or a bicyclic or tricyclic aromatic group having from 8 to 10 ring atoms, with one or more heteroatom(s) independently selected from N, O or S optionally substituted with 1 to 4 substituent(s) selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, acyl, carboxy, aryl, alkoxy, aralkyl, cyano, nitro, heterocyclyl, heteroaryl, —NR λ R π , CH═NOH, —(CH 2 ) w C(═O)R η {wherein w is an integer from 0-4 and R η is hydrogen, hydroxy, OR λ , NR λ R π , —NHOR ω or —NHOH}, —C(═O)NR λ R π —NHC(═O)NR λ R π , —SO m R ψ , —O—C(═O)NR λ R π , —O—C(═O)R λ , or —O—C(═O)OR λ (wherein m, R ψ , R λ and R π are as defined earlier and R ω is alkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl). Unless otherwise constrained by the definition, the substituents are attached to a ring atom, i.e., carbon or heteroatom in the ring. Examples of heteroaryl groups include oxazolyl, imidazolyl, pyrrolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, tetrazolyl, thiazolyl, oxadiazolyl, benzoimidazolyl, thiadiazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, thienyl, isoxazolyl, triazinyl, furanyl, benzofuranyl, indolyl, benzthiazinyl, benzthiazinonyl, benzoxazinyl, benzoxazinonyl, quinazonyl, carbazolyl phenothiazinyl, phenoxazinyl, benzothiazolyl or benzoxazolyl, and the like.
[0156] The term “heterocyclyl,” unless otherwise specified, refers to a non-aromatic monocyclic or bicyclic cycloalkyl group having 5 to 10 atoms wherein 1 to 4 carbon atoms in a ring are replaced by heteroatoms selected from O, S or N, and optionally are benzofused or fused heteroaryl having 5-6 ring members and/or optionally are substituted, wherein the substituents are selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, acyl, optionally substituted aryl, alkoxy, alkaryl, cyano, nitro, oxo, carboxy, optionally substituted heterocyclyl, optionally substituted heterocyclylalkyl, optionally substituted heteroaryl, —O—C(═O)R λ , —O—C(═O)OR λ ), —C(═O)NR λ R π , SO m R ψ , —O—C(═O)NR λ R π , —NHC(═O)NR λ R π , —NR λ R π , mercapto, haloalkyl, thioalkyl, —COOR ψ , —COONHR λ , —COR λ , —NHSO 2 R λ or SO 2 NHR λ (wherein m, R ψ , R λ and R π are as defined earlier) or guanidine. Heterocyclyl can optionally include rings having one or more double bonds. Such ring systems can be mono-, bi- or tricyclic. Carbonyl or sulfonyl group can replace carbon atom(s) of heterocyclyl. Unless otherwise constrained by the definition, the substituents are attached to the ring atom, i.e., carbon or heteroatom in the ring. Also, unless otherwise constrained by the definition, the heterocyclyl ring optionally may contain one or more olefinic bond(s). Examples of heterocyclyl groups include oxazolidinyl, tetrahydrofuranyl, dihydrofuranyl, benzoxazinyl, benzthiazinyl, imidazolyl, benzimidazolyl, tetrazolyl, carbaxolyl, indolyl, phenoxazinyl, phenothiazinyl, dihydropyridinyl, dihydroisoxazolyl, dihydrobenzofuryl, azabicyclohexyl, thiazolidinyl, dihydroindolyl, pyridinyl, isoindole 1,3-dione, piperidinyl, tetrahydropyranyl, piperazinyl, 3H-imidazo[4,5-b]pyridine, isoquinolinyl, 1H-pyrrolo[2,3-b]pyridine or piperazinyl and the like.
[0157] The term “carboxy,” as defined herein, refers to —C(═O)OH.
[0158] The term “amino” refers to —N(R i ) 2 , (wherein each R i is independently selected from hydrogen, alkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl).
[0159] “Acyl” refers to —C(═O)R″ wherein R″ is selected from hydrogen, alkyl, cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl.
[0160] The term “halo” refers to —F, —Cl, —Br, and —I.
[0161] The term “leaving group” refers to groups that exhibit or potentially exhibit the properties of being labile under the synthetic conditions and also, of being readily separated from synthetic products under defined conditions. Examples of leaving groups include, but are not limited to, halogen (e.g., F, Cl, Br, I), triflates, tosylate, mesylates, alkoxy, thioalkoxy, or hydroxy radicals and the like.
[0162] The term “protecting groups” refers to moieties that prevent chemical reaction at a location of a molecule intended to be left unaffected during chemical modification of such molecule. Unless otherwise specified, protecting groups may be used on groups, such as hydroxy, amino, or carboxy. Examples of protecting groups are found in T. W. Greene and P. G. M. Wuts, “Protective Groups in Organic Synthesis”, 2 nd Ed., John Wiley and Sons, New York, N.Y., which is incorporated herein by reference. The species of the carboxylic protecting groups, amino protecting groups or hydroxy protecting groups employed are not critical, as long as the derivatised moieties/moiety is/are stable to conditions of subsequent reactions and can be removed without disrupting the remainder of the molecule.
[0163] The term “pharmaceutically acceptable salts” refers to derivatives of compounds that can be modified by forming their corresponding acid or base salts. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acids salts of basic residues (such as amines), or alkali or organic salts of acidic residues (such as carboxylic acids), and the like. The term “pharmaceutically acceptable salts” refer to a salt prepared from pharmaceutically acceptable non-toxic inorganic or organic acid. Examples of such inorganic acids include, but are not limited to, hydrochloric, hydrobromic, hydroiodic, nitrous, nitric, carbonic, sulfuric, phosphoric acid, and the like. Appropriate organic acids include, but are not limited to aliphatic, cycloaliphatic, aromatic, heterocyclic, carboxylic and sulfonic classes of organic acids, for example, formic, acetic, propionic, succinic, glycolic, gluconic, lactic, malic, tartaric, citric, ascorbic, glucuronic, maleic, fumaric, pyruvic, aspartic, glutamic, benzoic, anthranilic, mesylic, salicylic, p-hydroxybenzoic, phenylacetic, mandelic, embonic, methanesulfonic, ethanesulfonic, benzenesulfonic, panthenic, toluenesulfonic, 2-hydroxyethanesulfonic acid and the like.
[0164] The term “pharmaceutically acceptable solvates” refers to solvates with water (i.e., hydrates) or pharmaceutically acceptable solvents, for example solvates with ethanol and the like. Such solvates are also encompassed within the scope of the disclosure. Furthermore, some of the crystalline forms for compounds described herein may exist as polymorphs and as such are intended to be included in the scope of the disclosure.
[0165] The present invention within its scope also includes prodrugs of these agents. In general, such prodrugs will be functional derivatives of these compounds, which are readily convertible in vivo into the active drugs. Conventional procedure for the selection and preparation of suitable prodrug derivatives are described, for example, in “Targeted prodrug design to optimize drug delivery”, AAPS PharmSci . (2000), 2(1), E6.
DETAILED DESCRIPTION OF THE INVENTION
[0166] The compounds disclosed herein may be prepared by techniques well known in the art and familiar to the skilled synthetic organic chemist. In addition, the compounds of the present invention may be prepared by the following reaction sequences as depicted in, for example, Schemes I to V.
[0000]
[0167] The compounds of formula VI can be prepared, for example, by following ‘Scheme I’.
[0000] Path a: The compound of formula II [wherein P is an amino protecting group selected from Boc, Fmoc, allyloxycarbonyl, benzyl, and Cbz] can be reacted with a compound of formula III (wherein L is a leaving group such as halide; R 7 , R 8 and R 9 are defined as earlier) to give the compound of formula V. The compound of formula V on deprotection can yield a compound of formula VI.
Path b: The compound of formula II can be reacted with a compound of formula IV (wherein M is O or S, and R 9 is defined as earlier) to form a compound of formula V. The compound of formula V on deprotection can yield a compound of formula VI.
[0168] The reaction of the compound of formula II with the compound of formula III (wherein R 7 is —CH 2 —, —CO— or —SO 2 — and R 8 is —O— or no atom) to give the compound of formula V (Path a) can be carried out in a solvent, for example, dichloromethane, toluene, dichloroethane, tetrahydrofuran, ether or dioxane and in the presence of a base, for example, triethylamine, diisopropylethylamine or N-methylmorpholine at a temperature of 0 to 100° C.
[0169] The reaction of the compound of formula II with a compound of formula III (wherein R 7 and R 8 are no atom) to give a compound of formula V (Path a) can be carried out in a solvent, for example, dimethylformamide, dioxane, tetrahydrofuran or dimethylsulphoxide and in the presence of a base, for example, potassium carbonate, triethylamine or N,N-diisopropylethylamine at a temperature of 0 to 150° C.
[0170] The reaction of the compound of formula II with the compound of formula IV to give a compound of formula V (Path b) can be carried out in a solvent, for example, dichloromethane, toluene, dichloroethane, tetrahydrofuran, ether or dioxane and, optionally, in the presence of a base, for example, potassium carbonate, triethylamine, diisopropylethylamine or N-methylmorpholine.
[0171] The deprotection of the compound of formula V to form the compound of formula VI can be carried out under acidic (e.g., p-toluenesulphonic acid or trifluoroacetic acid) or basic (e.g., piperidine) conditions in a solvent for example, acetonitrile, tetrahydrofuran or dioxane, dimethylformamide or a mixture thereof. The deprotection can also be carried out by other deprotection methods known to a skilled organic chemist.
[0000]
[0172] The compounds of formula X can be prepared, for example, by following ‘Scheme II’.
[0173] The compound of formula VII (wherein P is previously defined) can be reacted with a compound of formula VIII (wherein L is a leaving group such as halide and R 10 is alkyl) to give a compound of formula IX, which on deprotection can give a compound of formula X.
[0174] The reaction of the compound of formula VII with the compound of formula VIII to give the compound of formula IX can be carried out in a solvent, for example, tetrahydrofuran, dimethyl formamide, dimethylsulphoxide or dichloromethane and in the presence of a base, for example, sodium hydride, n-butyl lithium or silver carbonate at a temperature of −78 to 50° C. The deprotection of compound of formula IX can be carried out as that of the deprotection of the compound of formula V.
[0000]
[0000] The compound of formula Xc can be prepared, for example, by following Scheme II A.
[0175] The compound of formula Xa (wherein P is previously defined) can be reacted with trifluoroacetic anhydride to form a compound of formula Xb, which can then be deprotected to form a compound of formula Xc.
[0176] The reaction of compound of formula Xa with trifluoroacetic anhydride to form a compound of formula Xb can be carried out in the presence of one or more bases, for example, triethylamine, potassium carbonate or N,N-diisopropylethylamine in one or more halogenated solvents such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride, etc
[0177] The deprotection of compound of formula Xb to form a compound of formula Xc can be carried out as that of deprotection of compound of Formula V.
[0000]
[0178] The compound of formula XIII can be prepared, for example, by following ‘Scheme III’. Thus the compound of formula VI is reacted with a compound of formula XI (wherein P is an amino protecting group and A, E, and E′ are defined as earlier) to form a compound of formula XII, which is deprotected to give a compound of formula XIII.
[0179] The reaction of the compound of formula VI with a compound of formula XI to give a compound of formula XII can be carried out in a solvent, for example, tetrahydrofuran, dimethylformamide or dioxane using a coupling agent, for example, 1,3-dicyclo-hexylcarbodiimide (DCC), 1-ethyl-3-(3′-dimethylaminopropyl)carbodiimide hydrochloride (EDCI), N-[(dimethylamino)-1H-1,2,3-triazolo[4,5-b]pyridylmethylene]-N-methylmethanaminium hexafluorophosphate N-oxide (HATU) or benzotriazol-1-yl-N-oxy-tris(pyrrolidino)phosphonium hexafluorophosphate (PyBOP) and, optionally, a catalyst, for example, 1-hydroxybenzotriazole (HOBt), 3-hydroxy-3,4-dihydro-4-oxo-1,2,3-benzotriazine (HODhbt) or 7-aza-1-hydroxybenzo-triazole (HOAt) and, optionally, with a base, for example, N,N-dimethylaminopyridine (DMAP), triethylamine, N,N-diisopropylethylamine or N-methylmorpholine. The reaction can also be carried out by any other method well known for amide bond formation. The deprotection of the compound of formula XII to form the compound of formula XIII can be carried out as that of the deprotection of the compound of formula V.
[0000]
[0180] The compound of formula XV can be prepared, for example, by following ‘Scheme IV’.
[0181] Thus the compound of formula XI can be reacted with a compound of formula X (using the conditions similar to the coupling of the compounds of formulas VI and XI) to form a compound of formula XIV. The later compound can be deprotected to give a compound of formula XV (using the conditions similar to that of the deprotection of the compound of formula V).
[0000]
[0182] The compound of formula XX can be prepared, for example, by following Scheme V.
[0183] Thus, compound of formula X c can be reacted with compound of formula XI to form a compound of formula XVI, which can then be deprotected to form a compound of formula XVII. The compound of formula XVII can be reacted through three pathways to give a compound of formula XIX:
[0000] Path a: The compound of formula XVII can be reacted with a compound of formula III (wherein L is a leaving group such as halide; R 7 , R 8 and R 9 are defined as earlier) to give the compound of formula XIX;
Path b: The compound of formula XVII can be reacted with a compound of formula XVIII (wherein R 9 is defined as earlier) to give a compound of formula XIX; or
Path c: The compound of formula XVII can be reacted with a compound of formula IV (wherein M is O or S and R 9 is defined as earlier) to form a compound of formula XIX.
[0184] The compound of formula XIX can be deprotected to yield a compound of formula XX.
[0185] The reaction of compound of formula XI with a compound of formula Xc to form a compound of formula XVI can be carried out in one or more dry solvents, for example, dimethylformamide, tetrahydrofuran or dioxane using a coupling agent, for example, 1-ethyl-3-(3′-dimethylaminopropyl) carbodiimide hydrochloride (EDCI), 1,3-dicyclo-hexylcarbodiimide (DCC), N-[(dimethylamino)-1H-1,2,3-triazolo[4,5-b]pyridylmethylene]-N-methyl methanaminium hexafluorophosphate N-oxide (HATU) or benzotriazol-1-yl-N-oxy-tris(pyrrolidino)phosphonium hexafluorophosphate (PyBOP) in the presence of a peptide coupling agent, for example, 1-hydroxybenzotriazole (HOBt), 3-hydroxy-3,4-dihydro-4-oxo-1,2,3-benzotriazine (HODhbt) or 7-aza-1-hydroxybenzotriazole and, optionally, with a base, for example, triethylamine, N,N-dimethylaminopyridine (DMAP), N,N-diisopropylethylamine or N-methylmorpholine. The reaction can also be carried out by any other amide bond-formation method.
[0186] The conversion of the compound of formula XVI to a compound of formula XVII can be carried out under basic (e.g., potassium carbonate, piperidine) or acidic (e.g., p-toluenesulphonic acid and trifluoroacetic acid) conditions in a solvent, for example, methanol, acetonitrile, tetrahydrofuran, dioxane, dimethylformamide, or mixtures thereof.
[0187] The reaction of the compound of formula XVII with a compound of formula III (wherein L is a leaving group) to give a compound of formula XIXI (Path a) can be carried out in a solvent, for example, dichloromethane, dimethylformamide, dioxane, tetrahydrofuran or dimethylsulphoxide and in the presence of a base, for example, triethylamine, potassium carbonate, or N,N-diisopropyl-ethylamine.
[0188] The reductive amination of the compound of formula XVII with a compound of formula XVIII to give a compound of formula XIX (Path b) can be carried out in the presence of one or more reducing agents, for example, sodium triacetoxyborohydride, sodium cyanoborohydride or sodium borohydride in one or more chlorinated solvent, for example, dichloromethane, chloroform or carbon tetrachloride, polar protic solvents, for example, methanol, ethanol, propanol, isopropanol, water or polar aprotic solvent, for example, acetonitrile, or mixtures thereof.
[0189] The reaction of the compound of formula XVII with the compound of formula IV to give a compound of formula XIX (Path c) can be carried out in a solvent, for example, dichloromethane, toluene, dichloroethane, tetrahydrofuran, ether or dioxane, and optionally, in the presence of a base, for example, triethylamine, potassium carbonate, diisopropylethylamine or N-methylmorpholine.
[0190] The deprotection of the compound of formula XIX to form the compound of formula XX can be carried out under similar conditions as that of deprotection of compound of formula V.
[0191] In the above schemes, where specific bases, acids, solvents, coupling agents, protecting groups, hydrolyzing agents, etc., are mentioned, it is to be understood that other acids, bases, solvents, coupling agents, protecting groups, hydrolyzing agents, etc., known to those skilled in the art may also be used. Similarly, the reaction temperature and duration of the reactions may be adjusted according to the requirements that arise during the process.
[0192] The examples set forth below demonstrate the general synthetic procedures for the preparation of representative compounds. The examples are provided to illustrate some particular aspects of the disclosure and do not limit the scope of the present invention.
EXPERIMENTAL
Synthesis of 4-{N-(2,4-difluorobenzenesulphonyl)}amino-1-piperidine (pTSA Salt)
a. Step a: Synthesis of 4-{N-(2,4-difluorobenzenesulphonyl)}amino-1-(tert-butyloxycarbonyl)-piperidine
[0193] To a solution of 4-amino-1-(tert-butyloxycarbonyl)piperidine (1.000 g, 5.00 mmol) and triethylamine (0.15 mL, 10.5 mmol) in dichloromethane (10.0 mL) at 0° C., was added dropwise a solution of 2,4-difluorobenzenesulphonyl chloride (0.87 mL, 6.50 mmol) in dichloromethane (5.0 mL). The reaction mixture was stirred at room temperature for about 2-3 hours and partitioned between water (10.0 mL) and dichloromethane (15.0 mL). The aqueous layer was extracted with dichloromethane (15.0 mL). The combined organic layer was washed water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to yield the title compound (1.650 g), which was used as such in the next step.
[0194] 1 H NMR (300 MHz, CDCl 3 ): 1.20-1.50 (m, 1H), 1.70-1.85 (m, 2H), 2.7-2.9 (m, 2H), 3.25-3.45 (m, 1H), 3.8-4.05 (m, 2H), 4.69 (d, 1H, J=7.8 Hz), 6.9-7.1 (m, 2H), 7.80-8.00 (m, 1H);
[0195] ESI-MS (m/z): 377.1 (M + +1).
b. Step b: 4-{N-(2,4-difluorobenzenesulphonyl)}amino-1-piperidine (p TSA Salt)
[0196] To the compound (1.500 g, 4.18 mmol) obtained from ‘step a’ in acetonitrile (15.0 mL), was added p-toluenesulphonic acid (1.23 g, 6.49 mmol). The mixture was stirred for 12 hours at room temperature. The solvent was evaporated and the residue taken in ethyl acetate. The mixture was stirred for 30 minutes, and the precipitated solid filtered, washed with cold ethyl acetate and dried to yield the title compound (1.760 g, 82%).
[0197] 1 H NMR (400 MHz, MeOH-d4): δ 1.62-1.80 (m, 2H), 1.90-2.05 (m, 2H), 2.36 (s, 3H), 2.95-3.10 (m, 2H), 3.25-3.35 (m, 2H), 3.40-3.55 (s, 1H), 7.05-7.30 (m, 4H), 7.69 (d, 2H, J=7.8 Hz), 7.85-8.00 (m, 1H); ESI-MS (m/z): 277 (M + +1, free amine).
[0198] The following intermediates were prepared by following the preparation of 4-{N-(2,4-difluorobenzenesulphonyl)}amino-1-piperidine (pTSA salt) with the use of appropriate amine [4-(N-tert-butyloxycarbonyl)amino]piperidine, 4-amino-1-(tert-butyloxycarbonyl)piperidine, 6-(tert-butyloxycarbonyl)amino-3-azabicyclo [3.1.0]hexane or 2-(tert-butyloxycarbonyl)-2,5-diazabicyclo[2.2.1]heptane] and electrophile [acyl chloride, sulphonyl chloride or chloroformate]. In those cases, where the solid didn't precipitate (semi-solid) in step b, the solvent was decanted. Fresh ethyl acetate was added and, after stirring for 5 minutes, the solvent was decanted and the resulting semi-solid was dried under vacuum to afford the pure product.
4-Amino-1-(4-fluorobenzoyl)piperidine (pTSA salt)
[0200] [ESI-MS (m/z): 223.2 (M + +1), free amine];
4-Amino-1-(4-fluorobenzenesulphonyl)piperidine (pTSA salt)
[0202] [ESI-MS (m/z): 259.1 (M + +1), free amine];
4-Amino-1-{morpholin-1-carbonyl}piperidine (pTSA salt)
[0204] [ESI-MS (m/z): 214.3 (M + +1), free amine];
4-Amino-1-(methanesulphonyl)piperidine (pTSA salt)
[0206] [ESI-MS (m/z): 179 (M + +1), free amine];
4-(N-[4-Fluorobenzoyl])amino-1-piperidine (pTSA salt)
[0208] [ESI-MS (m/z): 223.2 (M + +1), free amine];
4-(N-[4-Fluorobenzenesulphonyl])amino-1-piperidine (pTSA salt)
[0210] [ESI-MS (m/z): 259.0 (M + +1), free amine];
4-(N-[Morpholin-1-carbonyl])amino-1-piperidine (pTSA salt)
[0212] [ESI-MS (m/z): 214 (M + +1), free amine];
4-(N-[Thiophene-2-carbonyl])amino-1-piperidine (pTSA salt)
[0214] [ESI-MS (m/z): 211 (M + +1), free amine];
4-(N-[Cyclopentyl-1-carbonyl])amino-1-piperidine (pTSA salt)
[0216] [ESI-MS (m/z): 197 (M + +1), free amine];
4-(N-[4-Cyanobenzenesulphonyl])amino-1-piperidine (pTSA salt)
[0218] [ESI-MS (m/z): 266 (M + +1), free amine];
4-(N-[Propan-2-sulphonyl])amino-1-piperidine (pTSA salt)
[0220] [ESI-MS (m/z): 208.22 (M + +1), free amine];
4-(N-[3-Fluoro-4-methoxybenzoyl])amino-1-piperidine (pTSA salt)
[0222] [ESI-MS (m/z): 253.15 (M + +1), free amine];
3-(Thiophen-2-sulphonyl)azabicyclo[3.1.0]hexan-6-amine (pTSA salt)
[0224] [ESI-MS (m/z): 245.1 (M + +1), free amine];
3-(4-Cyanobenzoyl)azabicyclo[3.1.0]hexan-6-amine (pTSA salt)
[0226] [ESI-MS (m/z): 360.41 (M + +1), free amine];
3-(2,6-Difluorobenzoyl)azabicyclo[3.1.0]hexan-6-amine (pTSA salt)
[0228] [ESI-MS (m/z): 370.51 (M + +1), free amine];
3-(4-Trifluorobenzenesulphonyl)azabicyclo[3.1.0]hexan-6-amine (pTSA salt)
[0230] [ESI-MS (m/z): 307.1 (M + +1), free amine];
3-(Thiophene-2-carbonyl)azabicyclo[3.1.0]hexan-6-amine (pTSA salt)
[0232] [ESI-MS (m/z): 209.1 (M + +1), free amine];
3-(Ethanesulphonyl)azabicyclo[3.1.0]hexan-6-amine (pTSA salt)
[0234] [ESI-MS (m/z): 191.2 (M + +1), free amine];
3-(4-Methylbenzenesulphonyl)azabicyclo[3.1.0]hexan-6-amine (pTSA salt)
[0236] [ESI-MS (m/z): 253.2 (M + +1), free amine];
4-(N-[2,2,2-Trifluoroethanesulphonyl])amino-1-piperidine (pTSA salt) 4-(N-[4-Cyanobenzenesulfonyl])amino-1-piperidine (pTSA salt)
[0239] [ESI-MS (m/z): 265.96 (M + +1), free amine];
4-(N-[2,4-Difluorobenzenesulfonyl])amino-1-piperidine (pTSA salt)
[0241] [ESI-MS (m/z): 277.01 (M + +1), free amine];
4-(N-[4-Methyl-2-methoxycarbonylthiophen-5-ylsulfonyl])amino-1-piperidine (pTSA salt)
[0243] [ESI-MS (m/z): 319 (M + +1), free amine];
4-(N-[1,3,5-Trimethylpyrazol-4-ylsulfonyl])amino-1-piperidine (pTSA salt)
[0245] [ESI-MS (m/z): 273.19 (M + +1), free amine];
4-(N-[2,5-Dimethyl-3-methoxycarbonylfuran-4-ylsulfonyl])amino-1-piperidine (pTSA salt)
[0247] [ESI-MS (m/z): 317.18 (M + +1), free amine];
4-(N-[4-Fluorobenzenesulfonyl])amino-1-piperidine (pTSA salt)
[0249] [ESI-MS (m/z): 259.10 (M + +1), free amine];
4-(N-[4-Acetylbenzenesulfonyl])amino-1-piperidine (pTSA salt)
[0251] [ESI-MS (m/z): 283.06 (M + +1), free amine];
4-(N-[2,4-Difluorobenzenesulfonyl])amino-1-piperidine (pTSA salt)
[0253] [ESI-MS (m/z): 277.10 (M + +1), free amine];
3-(N-Methylsulfonyl)amino-1-piperidine (pTSA salt)
[0255] [ESI-MS (m/z): 179.38 (M + +1), free amine];
3-(N-[4-Methyl-2-methoxycarbonyl thiophen-5-ylsulfonyl])amino-1-piperidine (pTSA salt)
[0257] [ESI-MS (m/z): 319 (M + +1), free amine];
3-(N-Isopropylsulfonyl)amino-1-piperidine (pTSA salt)
[0259] [ESI-MS (m/z): 207 (M + +1), free amine];
3-(N-Ethylsulfonyl)amino-1-piperidine (pTSA salt)
[0261] [ESI-MS (m/z): 193 (M + +1), free amine];
4-(N-Propanoyl)amino-1-piperidine (pTSA salt)
[0263] [ESI-MS (m/z): 157.23 (M + +1), free amine];
4-(N-Ethanoyl)amino-1-piperidine (pTSA salt)
[0265] [ESI-MS (m/z): 143.01 (M + +1), free amine];
4-(N-[3-Fluorobenzoyl])amino-1-piperidine (pTSA salt)
[0267] [ESI-MS (m/z): 223.12 (M + +1), free amine];
4-(N-[3,5-Difluoro-2-cyanophenyl])amino-1-piperidine (pTSA salt)
[0269] [ESI-MS (m/z): 238.09 (M + +1), free amine];
4-(N-Cyanophenyl)amino-1-piperidine (pTSA salt)
[0271] [ESI-MS (m/z): 202.12 (M + +1), free amine];
4-(N-[3,5-Difluoro-4-cyanophenyl])amino-1-piperidine (pTSA salt)
[0273] [ESI-MS (m/z): 238.09 (M + +1), free amine];
3-(N-[3,5-Difluoro-4-cyanophenyl])amino-1-piperidine (pTSA salt)
[0275] [ESI-MS (m/z): 238.16 (M + +1), free amine];
3-(N-[1-Cyanophenyl])amino-1-piperidine (pTSA salt)
[0277] [ESI-MS (m/z): 202.19 (M + +1), free amine];
3-(N-[4-Cyanophenyl])amino-1-piperidine (pTSA salt)
[0279] [ESI-MS (m/z): 202.19 (M + +1), free amine];
4-(N-[4-Cyanophenyl])amino-1-piperidine (pTSA salt)
[0281] [ESI-MS (m/z): 201.19 (M + +1), free amine];
4-(N-[2-Trifluoromethyl-4-cyanophenyl])amino-1-piperidine (pTSA salt)
[0283] [ESI-MS (m/z): 270.11 (M + +1), free amine];
2-Acetyl-2,5-diazabicyclo [2.2.1]heptane (pTSA salt)
[0285] [ESI-MS (m/z): 141 (M + +1), free amine];
2-[(4-Fluorophenyl)sulfonyl]-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0287] [ESI-MS (m/z): 257.11 (M + +1), free amine];
2-(Ethylsulfonyl)-2,5-diazabicyclo [2.2.1]heptane (pTSA salt)
[0289] [ESI-MS (m/z): 191 (M + +1), free amine];
2-(4-Cyano-3-trifluoromethylphenyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0291] [ESI-MS (m/z): 268 (M + +1), free amine];
2-(4-Fluorobenzoyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0293] [ESI-MS (m/z): 221 (M + +1), free amine];
2-(4-Fluorophenylaminocarbonyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0295] [ESI-MS (m/z): 221.18 (M + +1), free amine];
2-(2-Thienylsulfonyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0297] [ESI-MS (m/z): 245.20 (M + +1), free amine];
2-(4-Cyanophenylsulfonyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0299] [ESI-MS (m/z): 264.24 (M + +1), free amine];
2-[(3,5-Difluorophenyl)sulfonyl]-2,5-diazabicyclo [2.2.1]heptane (pTSA salt)
[0301] [ESI-MS (m/z): 275.22 (M + +1), free amine];
2-(Propylsulfonyl)-2,5-diazabicyclo [2.2.1]heptane (pTSA salt)
[0303] [ESI-MS (m/z): 205.25 (M + +1), free amine];
2-(Isopropylsulfonyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0305] [ESI-MS (m/z): 205.24 (M + +1), free amine];
2-(Butylsulfonyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0307] [ESI-MS (m/z): 219 (M + +1), free amine];
2-(Phenylsulfonyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0309] [ESI-MS (m/z): 239 (M + +1), free amine];
2-{[4-(Trifluoromethoxy)phenyl]sulfonyl}-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0311] [ESI-MS (m/z): 323 (M + +1), free amine]; and
2-(Methylsulfonyl)-2,5-diazabicyclo[2.2.1]heptane (pTSA salt)
[0313] [ESI-MS (m/z): 177.02 (M + +1), free amine]. Synthesis of 4-amino-1-[{N-(4-chlorophenyl)}aminocarbonyl]piperidine (pTSA salt)
a. Step a: Synthesis of 4-[(N-tert-butyloxycarbonyl)amino]-1-[{N-(4-chlorophenyl)}amino carbonyl]piperidine
[0314] To a solution of 4-[(N-tert-butyloxycarbonyl)amino]piperidine (0.500 g, 2.50 mmol) in dichloromethane (10.0 mL) at 0° C., was added dropwise a solution of 4-chlorophenyl isocyanate (0.38 mL, 3.0 mmol) in dichloromethane (5.0 mL). The mixture was stirred at RT for about 3 hours and partitioned between water (10.0 mL) and dichloromethane (20.0 mL). The organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to yield the title product, which was used directly in the next step.
[0315] 1 H NMR (400 MHz, MeOH-d4): δ 1.25-1.50 (m, 11H), 1.60 (s, 1H), 2.01 (d, 2H, J=8.0 Hz), 2.92-3.05 (m, 2H), 3.64-3.82 (br s, 1H), 3.99 (d, 2H, J=12.0 Hz), 4.40-4.55 (br s, 1H), 7.15-7.3 (m, 4H); ESI-MS (m/z): 376 (M + +23).
b. Step b: Synthesis of 1-[{N-(4-chlorophenyl)}aminocarbonyl]-4-aminopiperidine (pTSA Salt)
[0316] To the compound obtained from ‘step a’ in acetonitrile (7.0 mL), was added p-toluenesulphonic acid (0.713 g, 3.75 mmol) at room temperature. The reaction mixture was stirred for 12 hours. The solvent was evaporated and the crude mixture taken in ethyl acetate and stirred for 30 minutes. The precipitate was filtered, washed with cold ethyl acetate and dried under reduced pressure to yield the title compound (0.744 g, 70%)
[0317] 1 H NMR (400 MHz, MeOH-d4): δ 1.53-1.60 (m, 2H), 2.02 (d, 2H, J=16.0 Hz), 2.53 (s, 3H), 2.92-2.98 (m, 2H), 3.33-3.35 (m, 1H), 4.23 (d, 2H, J=16.0 Hz), 7.21-7.25 (m, 4H), 7.34 (d, 2H, J=8.0 Hz), 7.69 (d, 2H, J=8.0 Hz);
[0318] ESI-MS (m/z): 254 (M + +1, free amine)
[0319] The following intermediate was prepared by following the preparation of 1-[{N-(4-chlorophenyl)}aminocarbonyl]-4-aminopiperidine (pTSA salt) with the use of appropriate amine [4-amino-1-(tert-butyloxycarbonyl)piperidine] and electrophile [4-chlorophenyl isocyanate].
4-N-({4-Chlorophenyl}aminocarbonyl)-1-piperidine (pTSA salt)
[0321] [ESI-MS (m/z): 239.12 (M + +1), free amine];
Synthesis of (S)-3-(4-cyanobenzyl)oxy-1-pyrrolidine (pTSA Salt)
a. Step a: Synthesis of (S)—N-(tert-butylcarbonyloxy)-3-(4-cyanobenzyl)oxy-1-pyrrolidine
[0322] A solution of (S)—N-(tert-butylcarbonyloxy)-3-hydroxy-1-pyrrolidine (500 mg, 2.70 mmol) in anhydrous THF (2.0 mL) was added drop wise to a slurry of sodium hydride (60% dispersion in oil, 128 mg, 3.21 mmol) in THF (6.0 mL) at 0° C. under nitrogen atmosphere and the mixture stirred for 0.3 hours at 0° C. A solution of 4-cyanobenzyl bromide (576 mg, 2.94 mmol) in THF (3 mL) was added and the mixture warmed to room temperature and stirred for 18 hours. Water (20.0 mL) was added. The mixture was extracted with ethyl acetate (50.0 mL). The organic extract was washed with brine, dried over anhydrous sodium sulphate, and evaporated in vacuo. The crude product was chromatographed on silica gel (100-200 mesh) by eluting with 10% ethyl acetate in hexane to afford the colourless solid (500.0 mg, 76%)
[0323] 1 H NMR (400 MHz, CDCl 3 ): δ 1.48 (s, 9H), 1.82-2.19 (m, 2H), 3.35-3.57 (m, 4H), 4.15-4.25 (m, 1H), 4.50-4.65 (m, 2H), 7.45 (d, J=8.1 Hz, 2H), 7.66 (d, J=8.1 Hz, 2H)
b. Step b: Synthesis of (S)-3-(4-cyanobenzyl)oxy-1-pyrrolidine (pTSA Salt)
[0324] To a solution of the compound (600 mg, 1.99 mmol), obtained above, in acetonitrile (15.0 mL) was added pTSA (567 mg, 2.98 mmol) at ambient temperature. The mixture was stirred for 12 hours at room temperature. The solvent was evaporated and the residue taken in ethyl acetate. The mixture was stirred for 30 minutes, and the precipitated solid filtered, washed with cold ethyl acetate and dried to yield the title compound (642.0 mg, 86%).
[0325] 1 H NMR (300 MHz, MeOH-d4): δ 2.0-2.20 (m, 2H), 2.36 (s, 3H), 3.32-3.53 (m, 4H), 4.30-4.40 (m, 1H), 4.64 (s, 2H), 7.23 (d, J=8.1 Hz, 2H), 7.54 (d, J=8.1 Hz, 2H), 7.69-7.74 (m, 4H);
[0326] ESI-MS (m/z): 203.16 (M + +1, free amine).
[0327] The following intermediates were prepared by following the preparation of (S)-3-(4-cyanobenzyl)oxy-1-pyrrolidine (pTSA salt) from appropriate amine {(S)—N-(tert-butylcarbonyloxy)-3-hydroxy-1-pyrrolidine or (R)—N-(tert-butylcarbonyloxy)-3-hydroxy-1-pyrrolidine} and appropriate electrophile, by following the preparation of (S)-3-(4-cyanobenzyl)oxy-1-pyrrolidine (pTSA salt). In those cases, where the solid didn't precipitate (semi-solid) in step b, the solvent was decanted. Fresh ethyl acetate was added and, after stirring for 5 minutes, the solvent was decanted and the resulting semi-solid was dried under vacuum to afford the pure product.
(S)-3-(4-Fluorobenzyl)oxy-1-pyrrolidine (pTSA salt)
[0329] [ESI-MS (m/z): 196.13 (M + +1), free amine];
(R)-3-(4-Cyanobenzyl)oxy-1-pyrrolidine (pTSA salt)
[0331] [ESI-MS (m/z): 203.13 (M + +1), free amine]; and
(S)-3-(Ethoxycarbonyl)methyloxy-1-pyrrolidine (pTSA salt)
[0333] [ESI-MS (m/z): 174.09 (M + +1), free amine].
Synthesis of 2-(trifluoroacetyl)-2,5-diazabicyclo[2.2.1]heptane (p TSA Salt)
a. Step a: Synthesis of 2-(trifluoroacetyl)-2,5-diazabicyclo[2.2.1]heptane
[0334] Trifluoroacetic anhydride (0.9 mL, 6.55 mmol) was added dropwise to a solution of tert-butyl-2,5-diazabicyclo[2.2.1]heptane-2-carboxylate (1.0 g, 5.04 mmol) and triethylamine (2.2 mL, 15.1 mmol) in dichloromethane (5 mL) at 0° C. over a period of 30 minutes. The mixture was stirred at room temperature for about 2-3 hours and then partitioned between water and dichloromethane. The aqueous layer was extracted with dichloromethane, the combined organic layer was washed with brine, dried over anhydrous sodium sulfate and concentrated in vacuo to afford the title product (1.30 g, % yield: 87.2%)
[0335] 1 H NMR (400 MHz, MeOH-d4): δ 1.47 (s, 9H), 1.90-2.10 (m, 2H), 3.32-3.50 (m, 3H), 3.60-3.80 (m, 1H), 4.58 (brs, 1H), 4.82 (brs, 1H);
[0336] [ESI-MS (m/z): 295 (M + +1)].
b. Step b: Synthesis of 2-(trifluoroacetyl)-2,5-diazabicyclo[2.2.1]heptane (p TSA Salt)
[0337] p Toluenesulfonic acid (1.26 g, 6.63 mmol) was added to a solution of the compound (1.3 g, 4.4 mmol) obtained from above step in acetonitrile (20 mL) and this reaction mixture was stirred for 12 h at room temperature. The solvent was evaporated and the residue was dissolved in ethyl acetate. The mixture was again stirred for 30 minutes and the precipitated solid was filtered, washed with cold ethyl acetate and dried to afford the title compound (1.402 g, % yield: 87.1% (as salt))
[0338] 1 H NMR (400 MHz, MeOH-d4): δ 2.05-2.35 (m, 2H), 2.37 (s, 3H), 3.34-3.48 (m, 2H), 3.65-3.75 (m, 1H), 3.90 (s, 1H), 4.56 (s, 1H), 7.24 (d, J=8.0 Hz, 2H), 7.43 (d, J=8.0 Hz, 2H);
[0339] [ESI-MS (m/z): 195.2 (M + +1), free amine].
Example 1
Synthesis of (3R)—N-[1-{morpholin-1-carbonyl}piperidin-4-yl]-3-amino-4-[2,4,5-trifluoro phenyl]butanamide (TFA Salt) (Compound No. 01)
Step a: (3R)—N-[1-{morpholin-1-carbonyl}piperidin-4-yl]-3-(n-tert-butyloxycarbonyl)amino-4-[2,4,5-trifluorophenyl] butanamide
[0340] To a mixture of 4-ammonium-1-(morpholin-1-carbonyl)piperidine 4-toluenesulphonate (84 mg, 0.21 mmol), (3R)-3-[(N-tert-butoxycarbonyl)amino]-4-(2,4,5-trifluorophenyl)butanoic acid (70 mg, 0.21 mmol), triethylamine (0.043 mL, 0.32 mmol) and 1-hydroxybenzotriazole (0.040 g, 0.26 mmol) in dichloromethane (4.0 mL) at 0° C. under N 2 atmosphere, was added EDCI (0.059 g, 0.31 mmol). The reaction mixture was stirred at 0° C. for 30 minutes and then overnight at room temperature. The solvent was evaporated and the residue partitioned between ethyl acetate and water. The organic layer was washed with aqueous citric acid (10%), water, saturated aqueous sodium bicarbonate, water and brine. The organic layer was dried over anhydrous sodium sulphate, and concentrated under reduced pressure. The residue obtained, was purified by column chromatography using 10% methanol in dichloromethane (silica gel 100-200 mesh) as eluent to yield the title compound (88 mg, 79%).
[0341] 1 H NMR (400 MHz, CDCl 3 ): δ 1.37 (s, 9H), 1.92 (t, 2H, J=12.0 Hz), 2.25-2.53 (m, 2H), 2.75-2.95 (m, 4H), 3.24 (t, 4H, J=4.4 Hz), 3.67 (t, 6H, J=4.4 Hz), 3.82-4.1 (m, 2H), 5.36 (br d, 1H, J=8.0 Hz), 5.7 (br s, 1H), 6.80-6.92 (m, 1H), 7.00-7.10 (m, 1H);
[0342] ESI-MS (m/z): 529 (M + +1).
Step b: (3R)—N-[1-{morpholin-1-carbonyl}piperidin-4-yl]-3-amino-4-[2,4,5-trifluoro phenyl] butanamide (TFA Salt)
[0343] To a solution of compound (80 mg, 0.15 mmol) in dichloromethane (2.0 mL), obtained above, at 0° C. under N 2 atmosphere, a solution of trifluoroacetic acid (5.0 mL) in dichloromethane (15.0 mL) was added dropwise. The resulting mixture was stirred at room temperature for 3 hours. The solvent was evaporated and the residue washed with diethyl ether to obtain colourless solid (53.0 mg, 64%).
[0344] 1 H NMR (400 MHz, MeOH-d4): δ 1.3-1.5 (m, 2H), 2.40-2.60 (m, 2H), 2.84-3.10 (m, 4H), 3.2-3.35 (m, 8H), 3.6-3.7 (m, 6H), 3.72-3.9 (m, 2H), 7.15-7.35 (m, 2H);
[0345] ESI-MS (m/z): 429.3 (M + +1, free amine).
[0346] The following compounds were prepared as per the procedures given in Example 1 by coupling appropriate amines {4-amino-1-(substituted)piperidine, 4-(N-substituted)amino piperidine, 3-(O-substituted)oxypyrrolidine, 3-(N-substituted)azabicyclo[3.1.0]hexan-6-amine, 2-(N-substituted)2,5-diazabicyclo[2.2.1]heptane} with (3R)-3-[(N-tert-butoxycarbonyl)amino]-4-(2,4,5-trifluorophenyl) butanoic acid and using appropriate acid (e.g., 4-methylbenzenesulfonic acid, trifluoroacetic acid, methanolic-HCl) for deprotection. Respective free amines of the salt were prepared by taking the compound in ethyl acetate, and neutralization was carried out with 10% sodium bicarbonate.
Compound No. 2: (3R)-3-Amino-N-{1-[(4-fluorophenyl)sulphonyl]piperidin-4-yl}-4-(2,4,5-trifluorophenyl)butanamide and its 4-methylbenzenesulfonic acid salt
[0348] [ESI-MS (m/z): 474.2 (M + +1, free amine)];
Compound No. 3: (3R)-3-Amino-N-[1-(4-fluorobenzoyl)piperidin-4-yl]-4-(2,4,5-trifluorophenyl) butanamide and its 4-methylbenzenesulfonic acid salt
[0350] [ESI-MS (m/z): 438.1 (M + +1, free amine)];
Compound No. 4: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-fluorobenzamide and its trifluoroacetic acid salt
[0352] 1 H NMR (400 MHz, MeOH-d4): δ 1.40-1.60 (m, 2H), 1.80-2.10 (m, 2H), 2.66-2.90 (m, 3H), 3.08 (d, 2H, J=4.0 Hz), 3.16-3.28 (m, 1H), 3.80-3.95 (m, 2H), 4.05-4.18 (m, 1H), 4.51 (d, 1H, J=12.8 Hz), 7.15-7.40 (m, 4H), 7.80-7.92 (m, 2H);
Compound No. 5: (3R)-3-Amino-N-[1-(methylsulphonyl)piperidin-4-yl]-4-(2,4,5-trifluoro phenyl)butanamide and its 4-methylbenzenesulfonic acid
[0354] [ESI-MS (m/z): 393.91 (M + +1, free amine)];
Compound No. 6: (3R)-3-Amino-N-(3-hydroxy-1-adamantyl)-4-(2,4,5-trifluorophenyl) butanamide and its 4-methylbenzenesulfonic acid salt
[0356] [ESI-MS (m/z): 382.91 (M + +1, free amine)];
Compound No. 7: 4-{[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]amino}-N-(4-chloro phenyl)piperidine-1-carboxamide and its hydrochloride salt
[0358] [ESI-MS (m/z): 468.96 (M + +1, free amine)];
Compound No. 8: (3R)-3-Amino-N-[(1R,5S)-3-(2-thienylsulphonyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt
[0360] [ESI-MS (m/z): 457.87 (M + +1, free amine)];
Compound No. 9: (3R)-3-Amino-N-[(1R,5S)-3-(4-cyanobenzoyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt
[0362] [ESI-MS (m/z): 442.97 (M + +1, free amine)];
Compound No. 10: (3R)-3-Amino-N-[(1R,5S)-3-(2,6-difluorobenzoyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt
[0364] [ESI-MS (m/z): 453.96 (M + +1, free amine)];
Compound No. 11: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-fluorobenzenesulfonamide and its trifluoroacetic acid salt
[0366] [ESI-MS (m/z): 473.89 (M + +1, free amine)];
Compound No. 12: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}morpholine-4-carboxamide and its trifluoroacetic acid salt
[0368] [ESI-MS (m/z): 428.95 (M + +1, free amine)];
Compound No. 13: 1-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-3-(4-chlorophenyl)urea and its trifluoroacetic acid salt
[0370] [ESI-MS (m/z): 470.79 (M + +1, free amine)];
Compound No. 14: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-3-fluoro-4-methoxybenzamide and its trifluoroacetic acid salt
[0372] [ESI-MS (m/z): 467.91 (M + +1, free amine)];
Compound No. 15: N-{1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-2-propanesulfonamide and its trifluoroacetic acid salt
[0374] [ESI-MS (m/z): 421.93 (M + +1, free amine)];
Compound No 16: (3R)-3-Amino-N-[(1R,5S)-3-(4-trifluorobenzenesulphonyl)-3-azabicyclo [3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt
[0376] [ESI-MS (m/z): 521.71 (M + +1, free amine)];
Compound No. 17: (3R)-3-Amino-N-[(1R,5S)-3-(thiophene-2-carbonyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt
[0378] [ESI-MS (m/z): 423.78 (M + +1, free amine)];
Compound No. 18: (3R)-3-Amino-N-[(1R,5S)-3-(ethanesulphonyl)-3-azabicyclo[3.1.0]hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt
[0380] [ESI-MS (m/z): 405.79 (M + +1, free amine)];
Compound No. 19: (3R)-3-Amino-N-[(1R,5S)-3-(4-methylbenznesulphonyl)-3-azabicyclo[3.1.0] hex-6-yl]-4-(2,4,5-trifluorophenyl)butanamide and its trifluoroacetic acid salt
[0382] [ESI-MS (m/z): 467.81 (M + +1, free amine)];
Compound No. 20: 4-[({(3R)-1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]pyrrolidin-3-yl}oxy)methyl]benzonitrile and its trifluoroacetic acid salt
[0384] [ESI-MS (m/z): 417.96 (M + +1, free amine)];
Compound No. 21: (2R)-4-{(3S)-3-[(4-Fluorobenzyl)oxy]pyrrolidin-1-yl}-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0386] [ESI-MS (m/z): 410.84 (M + +1, free amine)];
Compound No. 22: 4-[({(3S)-1-[(3R)-3-Amino-4-(2,4,5-trifluorophenyl)butanoyl]pyrrolidin-3-yl}oxy)methyl]benzonitrile and its trifluoroacetic acid salt
[0388] [ESI-MS (m/z): 417.84 (M + +1, free amine)];
Compound No. 23: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-2,2,2-trifluoroethanesulfonamide and its trifluoroacetic acid salt
[0390] [ESI-MS (m/z): 462.04 (M + +1, free amine)];
Compound No. 24: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-cyanobenzenesulfonamide and its trifluoroacetic acid salt
[0392] [ESI-MS (m/z): 480.78 (M + +1, free amine)];
Compound No. 25: N-{1-[3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-2,4-difluorobenzenesulfonamide and its trifluoroacetic acid salt
[0394] [ESI-MS (m/z): 491.79 (M + +1, free amine)];
Compound No. 26: Methyl 5-[({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino) sulfonyl]-4-methylthiophene-2-carboxylate
[0396] [ESI-MS (m/z): 534.10 (M + +1, (m/z)];
Compound No. 27: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-1,3,5-trimethyl-1H-pyrazole-4-sulfonamide
[0398] [ESI-MS (m/z): 488.10 (M + +1, (m/z)];
Compound No. 28: methyl 4-[({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)sulfonyl]-2,5-dimethyl-3-furoate
[0400] [ESI-MS (m/z): 532.18 (M + +1, (m/z)];
Compound No. 29: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-fluorobenzenesulfonamide
[0402] [ESI-MS (m/z): 474.14 (M + +1, (m/z)];
Compound No. 30: 4-acetyl-N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl] piperidin-4-yl}benzenesulfonamide and its trifluoroacetic acid salt
[0404] [ESI-MS (m/z): 532.18 (M + +1, free amine)];
Compound No. 31: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-2,4-difluorobenzenesulfonamide and its trifluoroacetic acid salt
[0406] [ESI-MS (m/z): 492 (M + +1, free amine)];
Compound No. 32: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} methane sulfonamide and its trifluoroacetic acid salt
[0408] [ESI-MS (m/z): 394 (M + +1, free amine)];
Compound No. 33: methyl 5-[({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl] piperidin-4-yl} amino) sulfonyl]-4-methylthiophene-2-carboxylate and its trifluoroacetic acid salt
[0410] [ESI-MS (m/z): 534 (M + +1, free amine)];
Compound No. 34: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} propane-2-sulfonamide and its trifluoroacetic acid salt
[0412] [ESI-MS (m/z): 422 (M + +1, free amine)];
Compound No. 35: N-{(3S)-1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-3-yl}ethane sulfonamide and its trifluoroacetic acid salt
[0414] [ESI-MS (m/z): 408 (M + +1, free amine)];
Compound No. 36: 4-(1,3-dihydro-2H-isoindol-2-yl)-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0416] [ESI-MS (m/z): 335.10 (M + +1, free amine)];
Compound No. 37: N-{1-[3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} propanamide and its trifluoroacetic acid salt
[0418] [ESI-MS (m/z): 372.10 (M + +1, free amine)];
Compound No. 38: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}acetamide and its trifluoroacetic acid salt
[0420] [ESI-MS (m/z): 358.13 (M + +1, free amine)];
Compound No. 39: N-{1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl}-4-fluorobenzamide
[0422] [ESI-MS (m/z): 438.19 (M + +1, (m/z)];
Compound No. 40: 2-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)-4,6-difluorobenzonitrile and its trifluoroacetic acid salt
[0424] [ESI-MS (m/z): 453.22 (M + +1, free amine)];
Compound No. 41: 2-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)benzonitrile and its trifluoroacetic acid salt
[0426] [ESI-MS (m/z): 417.20 (M + +1, free amine)];
Compound No. 42: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)-2,6-difluorobenzonitrile and its 4-methylbenzenesulfonic acid salt
[0428] [ESI-MS (m/z): 453.22 (M + +1, free amine)];
Compound No. 43: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)-2,6-difluorobenzonitrile and its trifluoroacetic acid salt
[0430] [ESI-MS (m/z): 452 (M + +1, free amine)];
Compound No. 44: 2-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)benzonitrile and its trifluoroacetic acid salt
[0432] [ESI-MS (m/z): 417.29 (M + +1, free amine)];
Compound No. 45: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)benzonitrile and its trifluoroacetic acid salt
[0434] [ESI-MS (m/z): 417.20 (M + +1, free amine)];
Compound No. 46: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)benzonitrile and its trifluoroacetic acid salt
[0436] [ESI-MS (m/z): 417 (M + +1, free amine)];
Compound No. 47: 4-({1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]piperidin-4-yl} amino)-2-(trifluoromethyl)benzonitrile and its trifluoroacetic acid salt
[0438] [ESI-MS (m/z): 485 (M + +1, free amine)];
Compound No. 48: Ethyl ({(3S)-1-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]pyrrolidin-3-yl}oxy)acetate and its trifluoroacetic acid salt
[0440] [ESI-MS (m/z): 389.27 (M + +1, free amine)];
Compound No. 53: (2R)-4-(5-acetyl-2,5-diazabicyclo[2.2.1]hept-2-yl)-4-oxo-1-(2,4,5-trifluoro-phenyl)butan-2-amine and its trifluoroacetic acid salt
[0442] [ESI-MS (m/z): 356.31 (M + +1, free amine)];
Compound No. 60: (2R)-4-{5-[(3-fluorophenyl)sulfonyl]-2,5-diazabicyclo[2.2.1]hept-2-yl}-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0444] [ESI-MS (m/z): 472 (M + +1, free amine)];
Compound No. 71: (2R)-4-[5-(ethylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0446] [ESI-MS (m/z): 406.24 (M + +1, free amine)];
Compound No. 74: 4-{5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo-[2.2.1]hept-2-yl}-2-(trifluoromethyl)benzonitrile and its trifluoroacetic acid salt
[0448] [ESI-MS (m/z): 483.12 (M + +1, free amine)];
Compound No. 76: (2R)-4-[5-(4-fluorobenzoyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0450] [ESI-MS (m/z): 436.17 (M + +1, free amine)];
Compound No. 78: 5-[3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-fluorophenyl)-2,5-diaza-bicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0452] [ESI-MS (m/z): 451.25 (M + +1, free amine)];
Compound No. 81: (2R)-4-oxo-4-[5-(2-thienylsulfonyl)-2,5-diaza-bicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0454] [ESI-MS (m/z): 460 (M + +1, free amine)];
Compound No. 83: 4-({5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo [2.2.1]hept-2-yl}sulfonyl)benzonitrile and its trifluoroacetic acid salt
[0456] [ESI-MS (m/z): 479 (M + +1, free amine)];
Compound No. 85: (2R)-4-{(1S,4S)-5-[(3,5-difluorophenyl)sulfonyl]-2,5-diazabicyclo [2.2.1]hept-2-yl}-4-oxo-1-(2,4,5-trifluorophenyl) butan-2-amine and its trifluoroacetic acid salt
[0458] [ESI-MS (m/z): 490 (M + +1, free amine)];
Compound No. 90: (2R)-4-oxo-4-[5-(propylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0460] [ESI-MS (m/z): 420.26 (M + +1, free amine)];
Compound No. 91: (2R)-4-[5-(isopropylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0462] [ESI-MS (m/z): 420.40 (M + +1, free amine)];
Compound No. 92: (2R)-4-[5-(butylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0464] [ESI-MS (m/z): 434.30 (M + +1, free amine)];
Compound No. 93: (2R)-4-oxo-4-[5-(phenylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0466] [ESI-MS (m/z): 454.13 (M + +1, free amine)];
Compound No. 95: (2R)-4-oxo-4-(5-{[3-(trifluoromethoxy)phenyl]sulfonyl}-2,5-diazabicyclo [2.2.1]hept-2-yl)-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0468] [ESI-MS (m/z): 538.21 (M + +1, free amine)]; and
Compound No. 96: (2R)-4-[5-(methylsulfonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0470] [ESI-MS (m/z): 392 (M + +1, free amine)].
Example 2
Synthesis of (2R)-4-oxo-4-[5-(trifluoroacetyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine (HCl Salt) (Compound No. 50)
Step a: Synthesis of tert-butyl [(1R)-3-oxo-3-[5-(trifluoroacetyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorobenzyl)propyl]carbamate
[0471] To a solution of 2-(trifluoroacetyl)-2,5-diazabicyclo[2.2.1]heptane (p TSA salt) (0.88 g, 2.4 mmol) and (3R)-3-[(tert-butoxycarbonyl)amino]-4-(2,4,5-trifluorophenyl)butanoic acid (0.66 g, 2.0 mmol) in dry dimethylformamide, triethylamine (0.58 mL, 4.0 mmol) and n-hydroxybenzotriazole (0.39 g, 2.4 mmol) at 0° C. for 10 minutes and then 1-ethyl-3-(3′-dimethylaminopropyl)carbodiimide (0.5 g, 2.4 mmol) was added. After the removal of ice bath, reaction was allowed to stir at ambient temperature for about 14 hours. The reaction mixture was decomposed in cold water and the product was extracted using ethyl acetate. The organic layer was dried over anhydrous sodium sulfate and concentrated over vacuo. The residue thus obtained was purified by column chromatography over silica gel (100-200 mesh) using ethyl acetate and hexane as eluents to give the title product (0.43 g, % yield: 35.5%)
[0472] 1 H NMR (400 MHz, CDCl 3 ): δ 1.33 (s, 9H), 1.90-2.10 (m, 2H), 2.40-2.50 (m, 1H), 2.60-2.75 (m, 2H), 2.80-2.95 (m, 1H), 3.51-3.73 (m, 4H), 4.15 (brs, 1H), 4.66-4.92 (m, 1H), 7.05-7.44 (m, 2H);
[0473] ESI-MS (m/z): 510.30 (M + +1) (m/z).
Step b: Synthesis of (2R)-4-oxo-4-[5-(trifluoroacetyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine (HCl Salt)
[0474] The product obtained from the above step (0.05 g, 0.1 mmol) was dissolved in methanolic-HCl (2.5 N) and stirred for overnight at room temperature. The reaction mixture was concentrated and the residue was taken in diethyl ether, filtered and dried under vacuum to obtain the title compound (0.023 g, % yield: 57.5%)
[0475] 1 H NMR (400 MHz, CDCl 3 ): δ 1.8-2.1 (m, 2H), 2.35-3.05 (m, 4H), 3.30-3.83 (m, 5H), 4.35-4.70 (m, 2H), 7.11-7.32 (m, 2H);
[0476] ESI-MS (m/z): 410.18 (M + +1) (m/z).
Example 3
Synthesis of (2R)-4-oxo-4-(5-propionyl-2,5-diazabicyclo[2.2.1]hept-2-yl)-1-(2,4,5-trifluoro-phenyl)butan-2-amine (HCl Salt) (Compound No. 51)
Step a: Synthesis of tert-butyl [(1R)-3-(2,5-diazabicyclo[2.2.1]hept-2-yl)-3-oxo-1-(2,4,5-trifluorobenzyl)propyl]carbamate
[0477] To a solution of compound obtained in step a of Example 2 (0.1 g, 0.2 mmol) in methanol (2 mL) was added saturated solution of potassium carbonate (0.5 mL) at room temperature and this reaction mixture was stirred at the same temperature for overnight. The resultant mixture was concentrated and water (10 mL) was added to it. The compound was extracted out with ethyl acetate and the combined organic layers were dried over anhydrous sodium sulfate, concentrated and dried under vacuum to get the title compound (0.72 g, % yield: 87.5%)
[0478] 1 H NMR (400 MHz, CD3OD): δ 1.33 (s, 9H), 1.72-1.90 (m, 2H), 2.40-2.80 (m, 3H), 2.85-3.0 (m, 2H), 3.01-3.30 (m, 1H), 3.76 (d, J=10 Hz, 1H), 4.05-4.19 (m, 1H), 4.54-4.71 (m, 1H), 7.06-7.44 (m, 2H);
[0479] ESI-MS (m/z): 414.35 (M + +1) (m/z).
Step b: Synthesis of tert-butyl [(1R)-3-oxo-3-(5-propionyl-2,5-diazabicyclo[2.2.1]hept-2-yl)-1-(2,4,5-trifluorobenzyl)propyl]carbamate
[0480] To the solution of the compound as obtained in step a (0.1 g, 0.24 mmol), dry triethylamine (0.1 mL, 0.72 mmol) in dichloromethane (5 mL) was added a solution of propionyl chloride (0.03 mL, 0.32 mmol) dropwise at room temperature. The reaction mixture was stirred at same temperature for overnight and then partitioned between dichloromethane and water. The crude compound was extracted from aqueous layer using dichloromethane and combined layers were washed using brine, dried over anhydrous sodium sulfate and concentrated. The hence obtained compound was purified by column chromatography over silica gel (100-200 mesh) using ethyl acetate-hexane as eluents to get the title compound (0.72 g, % yield: 63.7%)
[0481] ESI-MS (m/z): 470 (M + +1) (m/z).
Step c: Synthesis of (2R)-4-oxo-4-(5-propionyl-2,5-diazabicyclo[2.2.1]hept-2-yl)-1-(2,4,5-trifluorophenyl) butan-2-amine (HCl Salt)
[0482] The compound obtained from step b (0.50 g, 0.11 mmol) was dissolved in methanolic-HCl (2.5 N) at room temperature. The reaction mixture was stirred for overnight and then concentrated. The resultant residue was stirred in diethyl ether for 10 minutes, filtered and dried to obtain the title compound (0.215 g, % yield: 52.8%)
[0483] 1 H NMR (400 MHz, MeOH-d4): δ 1.06-1.15 (m, 3H), 1.85-2.05 (m, 2H), 2.20-2.60 (m, 4H), 2.72-2.82 (m, 2H), 3.35-3.70 (m, 5H), 4.55-4.62 (m, 2H), 7.13-7.33 (m, 2H);
[0484] ESI-MS (m/z): 370.21 (M + +1).
[0485] The following compounds have been prepared using similar procedure using appropriate acid (e.g., 4-methylbenzenesulfonic acid, trifluoroacetic acid or methanolic-HCl) for deprotection as mentioned earlier.
Compound No. 49: (2R)-4-oxo-4-[5-(2-thienylacetyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0487] ESI-MS (m/z): 438.13 (M + +1) free amine.
Compound No. 52: 5-[(3R)-3-amino-4-(2,4,5-trifluoro phenyl)butanoyl]-N-(4-cyanophenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its 4-methylbenzenesulfonic acid salt
[0489] ESI-MS (m/z): 458.24 (M + +1), free amine.
Compound No. 54: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-fluoro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0491] ESI-MS (m/z): 451.34 (M + +1), free amine.
Compound No. 55: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-methoxy-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0493] ESI-MS (m/z): 463.30 (M + +1) free amine.
Compound No. 56: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[4-(trifluoro-methyl)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0495] ESI-MS (m/z): 501.33 (M + +1) free amine.
Compound No. 57: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-benzyl-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0497] ESI-MS (m/z): 447.31 (M + +1) free amine.
Compound No. 58: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-methyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0499] ESI-MS (m/z): 447.31 (M + +1) free amine.
Compound No. 59: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-tert-butyl-2,5-diaza-bicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0501] ESI-MS (m/z): 413.39 (M + +1) free amine.
Compound No. 61: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-fluoro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0503] ESI-MS (m/z): 451.33 (M + +1) free amine.
Compound No. 62: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[2-(trifluoromethyl)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0505] ESI-MS (m/z): 501.30 (M + +1) free amine.
Compound No. 63: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-methyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0507] ESI-MS (m/z): 447.37 (M + +1) free amine.
Compound No. 64: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-nitro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0509] ESI-MS (m/z): 478.33 (M + +1) free amine.
Compound No. 65: 4-{(1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diaza-bicyclo[2.2.1]hept-2-yl}-2-chlorobenzonitrile and its trifluoroacetic acid salt
[0511] ESI-MS (m/z): 449.22 (M + +1), free amine.
Compound No. 66: 2-{(1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diaza-bicyclo[2.2.1]hept-2-yl}-6-fluorobenzonitrile and its trifluoroacetic acid salt
[0513] ESI-MS (m/z): 433.32 (M + +1), free amine.
Compound No. 67: 4-{(1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diaza-bicyclo[2.2.1]hept-2-yl}-3-fluorobenzonitrile and its trifluoroacetic acid salt
[0515] ESI-MS (m/z): 433.32 (M + +1), free amine.
Compound No. 68: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-cyclohexyl-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0517] ESI-MS (m/z): 439.10 (M + +1), free amine.
Compound No. 69: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-methoxy-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0519] ESI-MS (m/z): 463.07 (M + +1), free amine.
Compound No. 70: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-fluoro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0521] ESI-MS (m/z): 451.02 (M + +1), free amine.
Compound No. 72: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,4-dimethoxyphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0523] ESI-MS (m/z): 493.06 (M + +1), free amine.
Compound No. 73: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-isopropyl-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0525] ESI-MS (m/z): 399.08 (M + +1), free amine.
Compound No. 75: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[4-(benzyl-oxy)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0527] ESI-MS (m/z): 555.06 (M + +17), free amine.
Compound No. 77: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3,4,5-tri-methoxyphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0529] ESI-MS (m/z): 523.06 (M + +1), free amine.
Compound No. 79: (1S,4S)-5-[3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,6-diisopropyl phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0531] ESI-MS (m/z): 517.10 (M + +1), free amine.
Compound No. 80: methyl 2-[({(1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diaza-bicyclo[2.2.1]hept-2-yl}carbonyl)amino]benzoate and its trifluoroacetic acid salt
[0533] ESI-MS (m/z): 491.05 (M + +1), free amine.
Compound No. 82: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(5-chloro-2-methoxy phenyl)-2,5-diazabicyclo [2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0535] ESI-MS (m/z): 497.01 (M + +1), free amine.
Compound No. 84: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,3-dichlorophenyl)-2,5-diazabicyclo [2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0537] ESI-MS (m/z): 500.90 (M + +1), free amine.
Compound No. 86: (1S,4S)—N-(4-acetylphenyl)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)-butanoyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0539] ESI-MS (m/z): 475.05 (M + +1), free amine.
Compound No. 87: methyl 5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxylate and its trifluoroacetic acid salt
[0541] ESI-MS (m/z): 372 (M + +1) free amine.
Compound No. 88: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,5-dimethoxyphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0543] ESI-MS (m/z): 493.06 (M + +1), free amine
Compound No. 89: ethyl 5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo [2.2.1]heptane-2-carboxylate and its trifluoroacetic acid salt
[0545] ESI-MS (m/z): 386 (M + +1) free amine.
Compound No. 94: (2R)-4-[5-(morpholin-4-ylcarbonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine and its trifluoroacetic acid salt
[0547] ESI-MS (m/z): 427.35 (M + +1) free amine.
Compound No. 97: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,6-difluoro-phenyl)-2,5-diazabicyclo [2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0549] ESI-MS (m/z): 469.03 (M + +1), free amine.
Compound No. 98: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,4,6-trifluoro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0551] ESI-MS (m/z): 487.04 (M + +1), free amine.
Compound No. 99: (1S,4S)—N-(3-acetylphenyl)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl) butanoyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0553] ESI-MS (m/z): 475.05 (M + +1), free amine.
Compound No. 100: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,5-dichloro-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0555] ESI-MS (m/z): 500.97 (M + +1), free amine.
Compound No. 101: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-isopropyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0557] ESI-MS (m/z): 475.05 (M + +1) free amine.
Compound No. 102: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-butyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0559] ESI-MS (m/z): 489.08 (M + +1) free amine.
Compound No. 103: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-ethoxy-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0561] ESI-MS (m/z): 477.07 (M + +1) free amine.
Compound No. 104: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-ethyl-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0563] ESI-MS (m/z): 461.06 (M + +1) free amine.
Compound No. 105: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-isopropyl-6-methylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0565] ESI-MS (m/z): 489.08 (M + +1) free amine.
Compound No. 106: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-mesityl-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0567] ESI-MS (m/z): 475.13 (M + +1) free amine.
Compound No. 107: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-methoxy-2-methylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0569] ESI-MS (m/z): 477.04 (M + +1) free amine.
Compound No. 108: (1S,4S)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-phenoxy-phenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0571] ESI-MS (m/z): 525.05 (M + +1) free amine.
Compound No. 109: (2R)-4-[(1R,4R)-5-(cyclohexylcarbonyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl) butan-2-amine and its trifluoroacetic acid salt
[0573] ESI-MS (m/z): 424.06 (M + +1) free amine.
Compound No. 110: (2R)-4-[(1R,4R)-5-(cyclopropyl carbonyl)-2,5-diazabicyclo [2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl) butan-2-amine and its trifluoroacetic acid salt
[0575] ESI-MS (m/z): 382.06 (M + +1) free amine.
Compound No. 112: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-ethoxyphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0577] ESI-MS (m/z): 477.04 (M + +1) free amine.
Compound No. 113: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-ethylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0579] ESI-MS (m/z): 461.05 (M + +1) free amine.
Compound No. 114: methyl 3-[({(1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-2,5-diazabicyclo[2.2.1]hept-2-yl}carbonyl)amino]benzoate and its trifluoroacetic Acid Salt
[0581] ESI-MS (m/z): 493.05 (M + +1) free amine.
Compound No. 115: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(4-ethylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0583] ESI-MS (m/z): 461.05 (M + +1) free amine.
Compound No. 116: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-chloro-4-methylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0585] ESI-MS (m/z): 480.99 (M + +1) free amine.
Compound No. 117: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[3-(methylthio)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0587] ESI-MS (m/z): 479.02 (M + +1) free amine.
Compound No. 118: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,4-difluorophenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0589] ESI-MS (m/z): 469.02 (M + +1) free amine.
Compound No. 119: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2,4-dimethylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0591] ESI-MS (m/z): 461.06 (M + +1) free amine.
Compound No. 120: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3,4-dichlorophenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0593] ESI-MS (m/z): 502.92 (M + +1) free amine.
Compound No. 121: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[4-chloro-3-(trifluoromethyl)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0595] ESI-MS (m/z): 534.93 (M + +1) free amine.
Compound No. 122: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(3-cyanophenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0597] ESI-MS (m/z): 458.00 (M + +1) free amine.
Compound No. 123: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-(2-isopropylphenyl)-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0599] ESI-MS (m/z): 475.07 (M + +1) free amine.
Compound No. 124: (1R,4R)-5-[(3R)-3-amino-4-(2,4,5-trifluorophenyl)butanoyl]-N-[3,5-bis(trifluoromethyl)phenyl]-2,5-diazabicyclo[2.2.1]heptane-2-carboxamide and its trifluoroacetic acid salt
[0601] ESI-MS (m/z): 568.93 (M + +1) free amine.
Example 4
Synthesis of (2R)-4-[(1R,4R)-5-(3,5-difluorobenzyl)-2,5-diazabicyclo[2.2.1] hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine (TFA Salt) (Compound No. 111)
Step a: Synthesis of tert-butyl [(1R)-3-[(1S,4S)-5-(3,5-difluorobenzyl)-2,5-diazabicyclo[2.2.1]-hept-2-yl]-3-oxo-1-(2,4,5-trifluorobenzyl)propyl]carbamate
[0602] An ice-cooled solution of the compound obtained from step a of Example 3 (0.1 g, 0.27 mmol) and 3,5-difluorobenzaldehyde (0.038 g, 0.27 mmol) in dry dichloromethane (5 ml) was treated with sodiumtriacetoxyborohydride (0.17 g, 0.8 mmol) and stirred at room temperature for 20 hours. The reaction mixture was cooled to 0° C., quenched with saturated ammonium chloride solution and extracted with dichloromethane. The combined organics were washed with water, brine, dried over anhydrous sodium sulfate and concentrated under vacuo to obtain the crude product that was purified by flash column chromatography using hexane/ethyl acetate (85:15) to give the title compound (0.1 g, 69%)
[0603] ESI-MS (m/z): 540.09 (M + +1) (m/z).
Step b: (2R)-4-[(1R,4R)-5-(3,5-difluorobenzyl)-2,5-diazabicyclo[2.2.1]hept-2-yl]-4-oxo-1-(2,4,5-trifluorophenyl)butan-2-amine (TFA Salt)
[0604] The compound obtained from step a (0.10 g, 0.18 mmol) was dissolved in dichloromethane (5 ml) and added trifluoroacetic acid (0.35 ml, 4.7 mmol) into it at room temperature. The reaction mixture was stirred for overnight and then concentrated. The resultant residue was stirred in diethyl ether for 10 minutes, filtered and dried to obtain the title compound (0.056 g, % yield: 70.7%)
[0605] 1 H NMR (400 MHz, MeOH-d4): δ 7.32-7.34 (m, 1H), 7.21-7.24 (m, 3H), 7.08-7.20 (m, 1H), 4.6-4.80 (m, 1H), 4.2-4.5 (m, 2H), 3.75-3.90 (m, 2H), 3.45-3.63 (m, 2H), 3.04-3.3 (m, 3H), 2.45-2.9 (m, 2H), 2.25-2.42 (m, 2H), 2.05-2.2 (m, 1H);
[0606] ESI-MS (m/z): 440.05 (M + +1) (m/z).
DPP IV Assay
Materials:
[0607] H-Gly-Pro-7-amido-methylcoumarine (Gly-Pro-AMC; Cat. # G2761) and coumarine (AMC; Cat. # A9891) were purchased from Sigma. A stock solution of 1 mM Gly-Pro-AMC was prepared in 50 mM HEPES buffer, pH 7.8, containing 80 mM MgCl2, 140 mM NaCl and 1% BSA (working buffer). A solution of 1 mM AMC was prepared in 10% dimethylsulfoxide (DMSO). Aliquots were stored at −20° C.
DPP IV Assay:
[0608] The DPP IV enzyme activity was determined using the fluorometric assay with the substrate Gly-Pro-AMC, which is cleaved by DPP IV to release the fluorescent AMC leaving group. The test compounds were dissolved in 100% dimethylsulfoxide to get a final concentration of 10 mM. The compounds were diluted serially in 10% DMSO to get 10× concentrations of 10 nM, 100 nM, 1000 nM, 10 μM, 100 μM, and 1000 μM. The source of DPP IV was human plasma, which was procured from local blood bank. DPP IV (10 μl human plasma) was mixed in 96-well FluoroNunc plates with test compounds. The final concentrations of the compounds were 1 nM, 10 nM, 100 nM, 1000 nM, 10 μM and 100 μM in working buffer, which were pre-incubated at 25° C. for 15 minutes. The assay was also carried out with 1% DMSO (final concentration), lacking the compound, as vehicle control. The reaction was started by adding 20 μl of 0.1 mM H-Gly-Pro-AMC (40 μM final concentration), followed by mixing and incubation at 25° C. for 20 minutes. The reaction was arrested by adding 50 μl of 25% acetic acid. The fluorescence was measured at an excitation filter of 380 nM and emission filter of 460 nM.
[0609] The DPP IV releases AMC from Gly-Pro-AMC, which was quantitated as relative fluorescence units (RFU). The percentage of activity was calculated as follows:
[0000] =(100/RFU of vehicle control)×RFU of test(with compound)
IC 50 Determination
[0610] The IC 50 is defined as the concentration of the inhibitor required to inhibit 50% of the human DPP IV activity under specific assay conditions. The activity obtained at different concentrations of the compound was plotted as log (X) vs. % activity in y-axis. The IC 50 values were calculated using non-linear regression analysis (GradPad Prism4).
[0611] The compounds provided herein showed activity (IC 50 ) between 1 nM-10 μM following this assay, for example, from about 1900 nM to about 10.4 μM, or, for example, from about 500 nM to about 10.4 μM, or, for example, 200 nM to about 10.4 μM, or, for example, from about 75 nM to about 10.4 μM, or, for example, from about 40 nM to about 10.4 μM. | The present invention relates to β-amino acid derivatives as dipeptidyl peptidase-IV inhibitors and the processes for the synthesis of the same. This invention also relates to pharmacological compositions containing the compounds of the present invention, and methods of treating diabetes, especially type 2 diabetes, as well as prediabetes, diabetic dyslipidemia, metabolic acidosis, ketosis, satiety disorders, and obesity. These inhibitors can also be used to treat conditions manifested by a variety of metabolic, neurological, anti-inflammatory, and autoimmune disorders like inflammatory disease, multiple sclerosis, rheumatoid arthritis; viral, cancer and gastrointestinal disorders. The compounds of this invention can also be used for treatment of infertility arising due to polycystic ovary syndrome. | 2 |
BACKGROUND OF THE INVENTION
A wide variety of inorganic and organic pigments are used in the art to impart bright yellow shades to coating compositions designed for interior or exterior surfaces. The most widely used inorganic yellow pigment is chrome yellow, a primrose yellow shade of lead chromate, referred to in the "Color Index" under the designation Lead Sulfochromate CI-77603. Primrose chrome yellow is generally characterized by good color strength and bleed resistance, but suffers from poor lightfastness relative to commonly used organic yellow pigments.
Among the organic yellow pigments, yellow azo pigments prepared by coupling diazotized amines with a variety of coupling compounds are most commonly used. Two well-recognized types of azo yellow pigments have become established in the trade. The first type, known as "toluidine yellows" since a well-known member of the series is obtained by coupling a nitrotoluidine (3-nitro-4-amino toluene) with actoacetanilide, is generally characterized by moderate color strength and good light-fastness, but poor bleed resistance. One of the toluidine yellows, prepared from coupling diazotized 2-nitro-4-chloroaniline with acetoacet-o-chloroanilide, exhibits superior color strength and lightfastness, but comparably poor bleed resistance. The second type of product, known as "benzidine yellows" is prepared by coupling of tetrazotized derivatives of benzidine (4,4'-diaminobiphenyl) coupled with derivatives of acetoacetanilide. Benzidine yellows exhibit color strength in the order of at least two times that commonly found in the toluidine yellows but have suffered from the defect of poor lightfastness.
The art has long recognized the need for a yellow pigment which exhibits the color strength and lightfastness of the azo yellows in combination with the bleed resistance of the chrome yellows. One attempt to fill this need is disclosed in Johnson U.S. Pat. No. 3,032,546. This patent describes a yellow azo pigment, prepared by coupling diazotized 5-nitro-2-aminoanisole with acetoacet-o-anisidide, having high color strength good lightfastness, and improved bleed resistance. However, Johnson teaches that although this pigment exhibits less bleeding in conventional enamels and water-based paints than prior art toluidine yellows, it is still not free from bleeding and, consequently, must be used with caution whenever paints of different colors are being used at the same time.
This invention provides for new azo pigments having color strength and lightfastness comparable to commonly used organic yellow pigments coupled with the bleed resistance possessed by the chrome yellow pigments.
SUMMARY OF THE INVENTION
The present invention is directed to a yellow azo pigment of the following structural formula ##SPC1##
Where X is selected from the group consisting of hydrogen and chlorine, Y is selected from the group consisting of hydrogen and chlorine, and only one of X and Y can be hydrogen. The structural formula used to describe the pigments of the present invention is in accordance with the azo structural form conventionally used to describe the product resulting from the reaction of diazotized amines with appropriate coupling compounds. However, since it has been hypothesized in the literature that azo compounds may exist, wholly or partly, in the corresponding hydrazone form, the structural formula describing the azo pigments of the invention includes such tautomeric forms where they exist.
In conventional paint formulations and coating compositions the pigments of the invention provide hiding power, strength and intensity which approximate those of toluidine yellows and chrome yellows. Masstone light-fastness is superior to that exhibited by primrose chrome yellows and comparable to that exhibited by toluidine yellows. In addition, the pigments of the invention possess far better bleed resistance than that possessed by toluidine yellows and, in fact, possess bleed resistance approaching that of chrome yellows.
The pigments of the invention are prepared by coupling a diazotized dichloroaniline selected from the group consisting of 2,4-dichloroaniline and 2,5-dichloroaniline, to barbituric acid in an aqueous medium at temperatures of from about 0°C to 50°C. at a pH of from about 1 to 6.9. The resulting insoluble product is separated from the slurry, washed with water, dried and pulverized. The pigment can be stored in the form of a dry powder or aqueous press cake prior to use in coating compositions.
DETAILED DESCRIPTION OF THE INVENTION
The pH of the aqueous medium in which the coupling reaction is conducted can be maintained between about 1 and 6.9 by adjustment with a mild base, such as sodium carbonate or by conducting the coupling reaction in an aqueous solution buffered with sodium acetate. Although acceptable pigment can be obtained throughout the pH range of 1 to 6.9, in the case of unbuffered coupling it is preferred to adjust the coupling pH to between about 1 and 4 to insure obtainment of a product with optimum tinctorial properties. In the case of the buffered coupling procedure, it is preferred that the coupling pH be between about 4.5 and 6.5 for obtainment of a product with optimum tinctorial properties.
The temperature range over which the coupling reaction of the invention can be conducted successfully is from about 0°C. and 50°C. To obtain pigment with maximum scattering, i.e., high degree of hiding power in paint applications, the preferred coupling temperature range is from about 5°C. to 20°C.
DESCRIPTION OF THE TESTS
Masstone
To determine the masstone of each pigment tested 0.6 g. of the pigment tested is mixed with 1.2 g. of a typical lithographic varnish (an air-drying resin) according to the procedure described in the Journal of the Oil and Colour Chemists Association, No. 396, Vol. XXXVI, June 1953, page 283. The masstone formulations for each pigment tested is spread on white paper and visual comparisons are made.
Strength
The strength of each pigment tested is determined by mixing 0.09 g. of the masstone formulation with 10.0 g. of a zinc oxide paste prepared by mixing 98 parts of the lithographic varnish used to prepare the masstone formulation, one part of a typical varnish drier, and 150 parts of zinc oxide. The relative tinting strength of the pigments tested is determined visually after spreading each of the tinting formulations on white paper.
Hiding Power
Visual hiding occurs when a paint film is sufficiently thick to prevent one from seeing the substrate beneath the film. To determine the relative visual hiding power of the pigments tested, a typical paint composition containing the same pigment to binder ratio for each pigment is sprayed on conventional black and white Morest chart paper. The paper is coated with a thin paint film (less than hiding) at the top and gradually coated with thicker paint films to a point greater than hiding at the bottom of the paper. The point a which hiding occurs for each paint composition is visually determined.
Bleed Resistance
To determine the bleed resistance of each of the pigments tested, a typical industrial enamel, consisting of a nondrying oil-modified alkyd resin and nitrogen resin is ball-milled with equal amounts of pigments so that the resulting pigmented enamel contains the same weight ratio of pigment to binder for each pigment tested. The pigmented enamel is sprayed on a primed metallic surface to the point of visual hiding after which it is dried by flashing one hour and baking at 250°F. (121°C.) for 30 minutes. A portion of the painted surface is then masked. The remainder of the painted surface is sprayed with a topcoat of white enamel to the point of visual hiding, after which it is dried by flashing for one hour and baking at 250°F. (121°C.) for 30 minutes. The panels are visually inspected to determine the relative degree to which the pigment tested comes through the white enamel topcoat.
The invention will be further described in the following examples. Unless otherwise specified, all parts and percentages discussed hereinunder and elsewhere throughout the specification are by weight.
EXAMPLE 1
Ninety-nine grams of 2,4-dichloroaniline is slurried in a solution of 1260 g. of water and 300 ml. of hydrochloric acid (36.5%). The slurry is then heated to 80°C. to dissolve the amine. The amine hydrochloride solution is cooled to 0°C. to 5°C. with ice and, while maintaining the temperature at approximately 0°C., a solution of 42 g. of sodium nitrite in 100 g. of water is added over a period of 15 minutes, followed by a stirring period of 15 minutes, whereupon a clear solution of diazotized amine is formed.
In a separate container 16.8 g. of barbituric acid is dissolved in a solution of 39 g. of sodium carbonate in about 4200 g. of water, by stirring at a temperature of 26°C. to 28°C. The volume is then adjusted to the equivalent of 6000 ml. of water and the temperature adjusted to 5°C. to 10°C. with ice, whereupon the above-prepared diazotized amine is added beneath the surface of the barbituric acid solution in 85 to 90 minutes. At the end of this addition the pH of the resulting pigment slurry is approximately 1.0. To complete the coupling the pH of the slurry is adjusted to between about 3.0 and 4.0 by adding 111 g. of sodium carbonate dissolved in 300 g. of water. The resulting slurry of pigment is filtered and washed substantially free of soluble salts. After drying at about 60°C. and pulverizing, 181 g. of a brillant yellow pigment is obtained. The average surface area of the pigment is determined from the amount of nitrogen gas adsorbed on the surface of the pigment according to the procedure described in the Analyst, 88, No. 1044, 156-187 (March 1963) and found to be about 13 m 2 /g. After recrystallization from dimethyl formamide, the pigment is analyzed and found to contain 39.9% C, 1.99% H and 19.1% N (Calculated values for C 10 H 6 Cl 2 N 4 O 3 : 39.3% C, 1.99% H and 18.6% N).
This yellow azo pigment exhibits tinctorial properties, i.e., intensity, strength, hiding power and light-fastness, which approximate those of a conventional toluidine yellow made by coupling diazotized 2-nitro-4-chloroaniline with acetoacet-o-chloroanilide. The bleed resistance of this pigment is far superior to that of the toluidine yellow and approaches that of primrose chrome yellow.
EXAMPLE 2
The procedure of Example 1 is followed except that prior to isolation of the product the resultant slurry of pigment is heated with open steam to boiling and held at the boiling point for 15 minutes. The pigment is isolated as in Example 1 and found to have an average surface area of about 2 m 2 /g. determined as in Example 1. The pigment is found to be less opaque in masstone and weaker in tint than the pigment of Example 1, but has comparable bleed resistance and lightfastness to the pigment of Example 1.
EXAMPLE 3
Forty-eight grams of 2,4-dichloroaniline is slurried in a solution of 48.9 g. of hydrochloric acid (100%) and 560 g. of water, and the slurry is diluted to a volume equal to 790 ml. of water and is stirred at about 82°C. until all of the amine is dissolved. The solution is cooled to approximately 0°C. with ice, and while maintaining the temperature at approximately 0°C., a solution of 21.1 g. of sodium nitrite in 50 g. of water is added over a period of 10 to 12 minutes, followed by a stirring period of one hour whereupon a solution of the diazotized amine is formed.
In a separate container 39.6 g. of barbituric acid is dissolved in a solution of 87.9 g. of sodium hydroxide in about 2200 g. of water. When the solution is clear, a solution of 114 ml. of acetic acid (100%) diluted with an equal volume of water is added to the solution. The pH of the resulting solution is normally about 6.3. If the pH significantly differs from this value, it should be adjusted by suitable additions of acid or alkali. The volume of the solution is then adjusted to the equivalent of 2750 ml. of water, and the temperature adjusted to 5°C. to 10°C., whereupon the above-prepared diazotized amine is added beneath the surface of the barbituric acid solution in about 60 minutes. The pH of the final slurry of pigment is adjusted to a pH of about 4.5. The slurry is filtered without heating, washed substantialy free of soluble salts. After dryng at about 60°C., and pulverizing 85 g. of a brilliant yellow pigment is obtained.
The tinctorial properties, lightfastness, and bleed resistance of this pigment are substantially the same as those exhibited by the pigment of Example 1.
EXAMPLE 4
Forty-eight grams of 2,5-dichloroaniline is slurried in a solution of 74.7 g. of hydrochloric acid (100%) and 420 g. of water, and is stirred at 90°C. to 95°C. until the amine is dissolved, thereupon the volume is adjusted to the equivalent of 1200 ml. of water and the temperature is adjusted to about 75°C.
In a separate container 21.1 g. of sodium nitrite is dissolved in 375 g. of water and cooled to about 0°C. with ice, and the separately prepared amine solution is added to the sodium nitrite solution in about 15 minutes, while maintaining the temperature below 10°C., to form the diazotized amine. The excess nitrous acid is removed by addition of about 2 g. of sulfamic acid to the diazo solution.
In a seperate container 39.6 g. of barbituric acid is dissolved in a solution of 87.9 g. of sodium hydroxide in about 2500 g. of water. When the solution is clear, a solution of 114 ml. of acetic acid (100%) diluted with an equal volume of water is added to the solution. The pH of the resulting solution should be about 6.3 and should be adjusted to this value if it is significantly different. The volume is adjusted to the equivalent of 3300 ml. of water, and the temperature adjusted to 5°C. to 10°C., whereupon the separately prepared diazo is added beneath the surface of the barbituric acid solution in about 90 minutes. The pH of the final slurry is adjusted to about 3.7. The slurry is filtered without heating and washed substantially free of soluble salts. After drying at about 60°C. and pulverizing 87.8 g. of a light intense yellow pigment is obtained.
This pigment is more intense and exhibits greater hiding power than the pigment of Example 1, but is somewhat less lightfast. The bleed resistance of this pigment is comparable to that of the pigment of Example 1.
Control
This control demonstrates the critical nature of the positions the chlorine radicals occupy on the dichloroaniline ring.
The procedure of Example 4 is followed except that 48.6 g. of 3,4-dichloroaniline is used in place of 2,5-dichloroaniline. After drying and pulverizing as in Example 4, 87.3 g. of a red shade yellow pigment are obtained.
This pigment is somewhat stronger than the 2,5-dichloro-substituted pigment of Example 4 and somewhat weaker than the 2,4-dichloro-substituted pigment of Example 1, but is much less lightfast than either the 2,5-dichloro or the 2,4-dichloro pigments. Though the bleed resistance of this pigment is superior to that of toluidine yellows, the inferior lightfastness of this pigment renders it unsuitable for many applications. | Yellow azo pigment is prepared by coupling 2,4- or 2,5-dichloroaniline with barbituric acid. In coating compositions these pigments provide high color strength, hiding power, lightfastness and bleed resistance and are particularly useful in industrial finishes. | 2 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Serial Nos.: 60/307,041 and 60/305,647, both filed Jul. 16, 2001, and incorporated herein by reference for all purposes
FIELD OF THE INVENTION
[0002] The present invention generally relates to object-oriented programming and more specifically relates to creating an environment where an application server may continue running while its owner makes various kinds of changes to it by employing a versioning architecture for managing version changes for classes in object-oriented environments.
BACKGROUND INFORMATION
[0003] The Internet is operated by Internet Service Providers (ISPs). These ISP's provide access to literally millions upon millions of users who rely upon ISPs to provide rapid access to the many web sites that are available. The ISPs in turn rely upon the millions of users for income for access as well as income derived from advertising and other services. Thus the ISPs have a vested interest in keeping its users happy.
[0004] ISPs invest million of dollars in improvements to their networks and operating systems as well as hardware and associated software. There are times when new software must be employed in order to keep the operations of the ISP at a level that is acceptable to the many ISP customers. However, upgrading software can be fraught with dangers such as downtime of the ISP, incompatibility issues with existing systems and other operational issues relating to the upgrade.
[0005] Computer systems generally, and those specifically used by ISP's and others, typically include a combination of hardware (e.g., semiconductors, circuit boards, etc.) and software (e.g., computer programs). As advances in semiconductor processing and computer architecture push the performance of the computer hardware higher, more sophisticated computer software has evolved to take advantage of the higher performance of the hardware, resulting in computer systems today that are much more powerful than just a few years ago.
[0006] Computer systems typically include operating system software that controls the basic function of the computer, and one or more software application programs that run under the control of the operating system to perform desired tasks. For example, a typical server may have the following configuration:
[0007] Dell 6450 w/4 Intel 700 MHz Xeon Processors
[0008] 36 GB Ultra 3 SCSI Hard disk
[0009] 4 GB SDRAM
[0010] 2 Intel Pro 1000 Gigabit Network Interface Cards
[0011] and run any variety of Windows, Unix, or other operating systems and applications software. However, this is not a static picture. As the capabilities of computer systems have increased, the application software programs designed for high performance computer systems have become extremely powerful. Additionally, software development costs have continued to rise because more powerful and complex programs take more time, and hence more money, to produce.
[0012] One way in which the performance of application software programs has been improved while the associated development costs have been reduced is by using object-oriented programming concepts. The goal of using object-oriented programming is to create small, reusable sections of program code known as “objects” that can be quickly and easily combined and re-used to create new programs. This is similar to the idea of using the same set of building blocks again and again to create many different structures. The modular and re-usable aspects of objects will typically speed development of new programs, thereby reducing the costs associated with the development cycle. In addition, by creating and re-using a comprehensive set of well-tested objects, a more stable, uniform, and consistent approach to developing new computer programs can be achieved.
[0013] Object-oriented programming is a method of program implementation in which programs are organized as cooperative collections of objects, each of which represents an instance of some class, and whose classes are all members of a hierarchy of classes united via inheritance relationships. Object-oriented programming differs from standard procedural programming in that it uses objects, not algorithms, as the fundamental building blocks for creating computer programs. This difference stems from the fact that the design focus of object-oriented programming technology is wholly different than that of procedural programming technology.
[0014] The focus of procedural-based design is on the overall process used to solve the problem; whereas the focus of object-oriented design is on casting the problem as a set of autonomous entities that can work together to provide a solution. The autonomous entities of object-oriented technology are, of course, objects. Object-oriented technology is significantly different from procedural technology because problems are broken down into sets of cooperating objects instead of into hierarchies of nested computer programs or procedures.
[0015] Thus, a pure object-oriented program is made up of code entities called objects. Each object is an identifiable, encapsulated piece of code and data that provides one or more services when requested by a client. Conceptually, an object has two parts, an external object interface and internal object implementation. In particular, all object implementation functions are encapsulated by the object interface such that other objects must communicate with that object through its object interface. The only way to retrieve, process or otherwise operate on the object is through the methods and attributes exposed as the defined interface to the object. This protects the internal data portion of the object from outside tampering. Additionally, because outside objects have no access to the internal implementation, that internal implementation can change without affecting other aspects of the program.
[0016] In this way, the object system isolates the requester of services (client objects) from the providers of services (server objects) by a well defined encapsulating interface. In the classic object model, a client object sends request messages to server objects to perform any necessary or desired function. The message identifies a specific method to be performed by the server object, and also supplies any required parameters. The server object receives and interprets the message, and can then decide what service to perform.
[0017] There are many computer languages available today that support object-oriented programming. For example, Smalitalk, Object Pascal, C++ and JAVA are all examples of languages that support object-oriented programming to one degree or another.
[0018] A central concept in object-oriented programming is the “class.” A class is a template or prototype that defines a type of object. A class outlines or describes the characteristics or makeup of objects that belong to that class. By defining a class, objects can be created that belong to the class without having to rewrite the entire definition for each new object as it is created. This feature of object-oriented programming promotes the reusability of existing object definitions and promotes more efficient use of code.
[0019] Computer programs naturally evolve over time. The evolution of object-oriented computer programs entails defining new classes that have implementations different than previous versions. As time passes, the type and quantity of information stored by these objects may need to be changed or enhanced to accommodate additional or different data types. In this case, the definition of the class will, of necessity, be changed to support the new object data storage requirements. This scenario typically occurs when a program is upgraded from a first software version to a newer, more powerful version of the program. A new release of an existing program may use a combination of new classes and classes that were defined in a previous version. The processes and activities-associated with modifying, updating, and tracking changes in a class over a period of time are known as “versioning.”
[0020] It is important to note that, even though a program has been upgraded, it is frequently necessary to maintain both the existing objects that were created by the first version (belonging to one version of a class) and the new objects that are created by the newer version of the software application (belonging to a different version of the same class). In order to accomplish this, some mechanism should be provided to track the various names of the object classes as the versions of the software application are changed. Theoretically, it is possible to give each new class version the same name. However, in practice, many object-oriented programming languages, such as JAVA, require that each co-existing version of the class have a different name. This means that as time passes and multiple versions of the various classes are changed yet remain available for use, it can become very difficult to keep track of the many different names for each class and the related objects that are created.
[0021] For example, a large company that has been in business for many years may have changed the nature of the object used to store employee-related data as the information needs of the business developed. Beginning in 1970, the employee object tracked the name, address, phone number, date of hire, supervisor, and salary for each employee. In 1980 the definition of the objects in the employee class was changed to include information regarding 401K plans for the employee and in 1990 the definition for the employee class was changed again to include information regarding each employee's performance and evaluation reviews.
[0022] There are several solutions that have been previously implemented to address the versioning problems associated with multiple names for different versions of the same class. Typically, when a new version of a software application is to be implemented, the software application is recompiled and the system must be shut down. When the new version of the software application is loaded, the system will recognize that a new version has been created, load all the existing objects, and rebuild the objects one by one so that they are compatible with the new version of the software application. This process may also include a re-naming of all existing objects. While this solution is acceptable for systems with a limited number of objects, once the number of objects in the system exceeds a certain minimal level, the operational overhead associated with rebuilding each object in the system every time the version changes can quickly become unacceptable. This is especially true for systems that need to be operational “24/7/365,” such as for Internet service providers (ISPs), that cannot be “off-line” for recompiling, and therefore must usually provide redundant systems.
[0023] One typical solution for upgrading software applications has been to upgrade everything at once and provide dual mode operations until there were no applications that needed to use the old software. This “solution,” however, would be quite burdensome for large-scale ISPs. For example, a large ISP will have many pieces of hardware, operating system software and application software that is required to run the network. If the ISP has been in business a number of years, the objects and classes of objects may have changed as the information needs and operational needs of the ISP have developed. At its inception, the ISP may have tracked its subscriber information only. However as time progressed, this tracking of information has evolved in demographic information about users as well as the likes and dislikes, and surfing habits of the ISPs subscribers. This information requires different type of storage objects and application program from the early period of the existence of the ISP to the present day.
[0024] Another possible solution has been to create a sub-class for the new version of the objects as they are needed. This solution, while useful, has its own inherent limitations. Specifically, as each new version of the class is created, another level in the class hierarchy is established. After a period of time, tracking class versions through the nested hierarchy of classes and sub-classes becomes extremely inefficient and can measurably reduce system performance.
[0025] Without a mechanism for more easily and flexibly creating, managing, and tracking the various versions of object classes that must be utilized in a large-scale, frequently evolving object-oriented environment, the computer industry will continue to suffer from the effects of the inefficient versioning methods presently used to manage new class versions. In addition, the creation of objects according to the desired class version will continue to be more difficult and uncertain than necessary.
[0026] Others have attempted to address some of these same versioning issues. U.S. Pat. No. 5,974,428 discloses a class versioning and mapping system that allows a user to request a desired class without knowing which class version is the most recent or correct version for the desired class. This class versioning and mapping system uses a version mapping mechanism to cross reference the requested class, select the most recent or best version of the requested class, and then return an object to the user that belongs to the selected class.
[0027] U.S. Pat. No. 6,119,130 discloses a method and apparatus that allow schema version evolution to occur without requiring applications that expect older schema versions to be recompiled is provided. According to one aspect of the patent, each application that requests data is supplied the data in the format that the application expects. To supply the data in the expected format, a mechanism is provided for tracking the evolution of data types without losing information. In addition, mechanisms are provided for determining the format expected by the application and the format in which the data is currently stored. A mechanism is also provided for converting the data from the stored format to the expected format when the two formats do not match. A data migration strategy is described in which data is gradually migrated to newer formats when the data is updated by applications that expect a more recent format than the format in which the data is currently stored.
BRIEF SUMMARY OF THE INVENTION
[0028] In view of the above background it is therefore an object of the present invention to provide for smooth versioning of classes of objects.
[0029] It is another objective of the present invention to provide for on-the-fly addition and retraction of class attributes to improve the implementation of methods while providing backwards compatibility with older application clients.
[0030] It is another objective of the present invention to provide for on-the-fly addition and retraction of class associations with other classes to add new functionality to existing methods.
[0031] It is another object of the invention to provide for on-the-fly addition of polymorphic class operations to add new functionality for new application clients.
[0032] It is still another objective of the present invention to avoid upgrading all objects and classes of objects at once.
[0033] It is a further objective of the present invention to provide upgraded versions of classes gradually over time without losing any compatibility with existing objects.
[0034] It is a further objective of the present invention to store identification links that show the relationship of one class version to another.
[0035] It is still another objective of the present invention to transparently allow users to take advantage of new version functionality, even when the user believe they are using a prior version of software.
[0036] It is a further objective of the present invention to reduce system downtime due to recompiling of new classes.
[0037] It is yet another objective of the present invention to allow older objects to be used by new software.
[0038] These and other objectives of the present invention will be come apparent to those skilled in the art from a review of the specification that follows.
[0039] The present invention is an architecture for versioning of classes of objects “on the fly,” that is, without recompiling. The system and method of the present invention allows class versioning gradually over time as the system is used by system users.
[0040] Using this on the fly versioning, an ISP having a complex network architecture and many application programs can continually upgrade without the potential for entire system downtime.
[0041] The present invention accomplishes this by modeling the network and customers of, for example, a large ISP. It should be noted that while the example of an ISP is being used throughout this application, this is not meant as a limitation. Clearly the techniques, methods and architecture of the present invention can be used in any large data processing environment having disparate operating systems and application software.
[0042] The ISP operating system, software application programs and any other configurable software (hereinafter “versionable software”) are noted. As part of this modeling process, all service being offered and associations of data are noted. All of the internal properties of the network environment are noted and recorded.
[0043] Using this model information as a database, when one class is upgraded to a newer version, information on other pieces of data that are required to work with the new software are maintained. When users use the new software, and that new software calls upon, as necessary, the older object.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIGS. 1 A-D illustrate the overall process of a first embodiment of the present invention.
[0045] [0045]FIG. 2 illustrates top-level and mid-level class additions in accordance with a first embodiment of the present invention.
[0046] FIGS. 3 illustrates the consequences of bottom-level class additions in accordance with a first embodiment of the present invention.
[0047] [0047]FIG. 4 illustrates the consequences of mid-level class changes in accordance with a first embodiment of the present invention.
[0048] FIGS. 5 A-D illustrate the overall process of a second embodiment of the present invention.
[0049] [0049]FIG. 6 illustrates top-level and mid-level class additions in accordance with a second embodiment of the present invention.
[0050] FIGS. 7 illustrates the consequences of bottom-level class additions in accordance with a second embodiment of the present invention.
[0051] [0051]FIG. 8 illustrates the consequences of mid-level class changes in accordance with a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0052] The class versioning architecture of the present invention provides: on-the-fly addition and retraction of class attributes to improve the implementation of methods while providing backwards compatibility with older application clients; on-the-fly addition and retraction of class associations with other classes to add new functionality to existing methods; and on-the-fly addition of polymorphic class operations to add new functionality for new application clients.
[0053] To achieve this functionality, the present invention takes advantage of standard object-oriented programming concepts, including: standard polymorphism, a common object-oriented concept that allows many different kinds of classes to expose the same operations with different implementation methods; rules evaluation, a common concept that allows the owner of the application to invoke operations when one or more attributes take on a particular set of values; and privatization of class attributes, a common object-oriented concept that provides a way to hide the implementation-specific attributes of an implementation method.
[0054] The following set of examples demonstrates the consequences of:
[0055] 1) creating a class,
[0056] 2) creating a class that inherits from a top-level class,
[0057] 3) creating a class that inherits from a mid-level class, and
[0058] 4) changing a mid-level class.
[0059] These examples make a distinction between what a user sees as the system model (on the right in the following figures) and what a meta model compiler of the present invention generates for the running system. Every change creates a new version of one or more classes.
[0060] Although the present invention is drawn to class versioning, its primary utility is in combination with the present inventors'class transitioning invention, disclosed in co-pending application Attorney Docket No.: 2655-002.
[0061] FIGS. 1 A-D illustrate an overview of a first embodiment of class the versioning of the present invention in combination with instance transitioning, which is further described in FIGS. 2 - 4 . Although described with respect to a typical scenario, the invention is not meant to be so limited. A similar scenario is shown in FIGS. 5 A-D with respect to a second embodiment of the versioning of the present invention and its transitioning scheme and helpful in illustrating the differences between the two embodiments disclosed herein.
[0062] [0062]FIG. 1A illustrates the first step in which Router v 1 110 is created, committed (compiled and approved) by the meta model compiler 111 , and deployed. An instance of Router v 1 (Router# 1 ) 112 is created and the links 114 to Router# 1 v 1 are added. In a preferred embodiment, the present invention provides persistent storage 116 using the POET SQL Object Factory or “FastObjects” object oriented database mapping software available from POET Software of San Mateo, Calif.
[0063] [0063]FIG. 1B illustrates the second step. Here, Router v 2 120 is created, committed, and deployed. Router# 1 is then transitioned from v 1 to v 2 122 . The third step is illustrated in FIG. 1C, wherein Router v 3 130 is created, compiled, and deployed with Router# 1 transitioned from v 2 to v 3 132 . The final step is illustrated in FIG. 1D, wherein Router v 3 132 is rolled back to Router v 2 122 . There are advantages and disadvantages associated with this first embodiment of class versioning and the instance transitioning scheme of the present invention. This first embodiment uses an explicit class versioning scheme, which creates a new Java class for each new version of a type. In order to maintain backwards compatibility, a parent class versioning causes all of its subclasses get versioned.
[0064] An advantage to this scheme is that class versioning is explicitly controlled by the application. Each class versions are represented by different Java class definitions. Different Java class definitions for different class versions can co-exist in the running system. However, there are also disadvantages. Since instances of those classes need to be persisted, the number of persistence classes in the system can grow exponentially. Also, it makes access to the persisted objects (e.g., via Java Remote Method Invocation (RMI)) difficult since they have to deal with version numbers in interface and class names. And finally, a query on a type has to be explicitly executed on all the versioned classes.
[0065] This first embodiment uses the default class hierarchy mapping option (STORE DEFAULT) of the POET SQL OF RSMAP utility. With this default mapping option, each persistence class is mapped into a table in relational database. Each table of a subclass has all the columns inherited from its parent class in addition to its own columns. One row is inserted into the table of the class when an instance is saved into database. In order to support polymorphic query, POET RSMAP utility creates a “polymorphic” view for each parent class table, which ‘unions’ all the subclass tables.
[0066] POET SQL Object Factory supports three types (and certain combinations) of class inheritance mapping options: STORE DEFAULT, STORE ALL, and STORE UNIVERSAL. The following examples show the differences among the three options.
[0067] Assume that there are three classes—A, B, and C.
Class Base Class Members A None A1 B A (A1), B1 C B (A1, B1), C1 STORE DEFAULT option on A, B, and C: Class Generated Table (Columns) Rows in the Table A A (A1) Instances of Class A B B (A1, B1) Instances of Class B C C (A1, B1, C1) Instances of Class C STORE ALL option on B, and STORE DEFAULT on A and C: Class Generated Table (Columns) Rows in the Table A A (A1) Instances of Class A B B (A1, B1) Instances of Class B and C C C (A1, B1, C1) Instances of Class C STORE UNIVERSAL option on B, and STORE DEFAULT on A and C: Class Generated Table (Columns) Rows in the Table A A (A1) Instances of Class A B B (A1, B1, C1) Instances of Class B and C C
[0068] The STORE DEFAULT mapping option has the advantage that it provides overall well balanced performance for insert, update, delete, and search. A disadvantage of this option is that there is a big view at the level which ‘unions’ all the tables in the system. The SQL statement to create this view can be very large if there are many persistence classes in the system. POET RSMAP utility imposes a limit of 64 k bytes on how large the SQL statement can be handled. If the SQL statement exceeds this limit, the system receives an error from RSMAP utility, and mapping schema is not correctly created or updated. Because of this limitation, this embodiment can only handle, at most, a couple of hundreds of types including versions, which is not acceptable to many customers.
[0069] This first embodiment also creates new instances when transitioning old instances. It relies on the “pointers” in those instances to track superseding and preceding instances. This has the advantage that it can create instances of old class versions, and get old behavior of those versions. It also makes “rollback” quite easy. However, since this embodiment keeps old instances in the database, the size of the instance database can grow exponentially. In the same time, since it creates new instances for new class versions, maintaining correct and reliable links among instances can be a very complicated task.
[0070] Because this first embodiment relies on explicit class versioning scheme, it needs to run “TypeFilter” to substitute any occurrence of interface or class names in user code. Although this has the advantage of making the class versioning scheme transparent to users, it causes extra overhead in compilation and may introduce potential problems.
[0071] [0071]FIG. 2 illustrates the consequences of top-level and mid-level class additions. When a user creates the classes ForwardingDevice 210 and IpForwarder 220 , the meta model compiler will generate two classes for each user-visible class:
[0072] an interface class (ForwardingDeviceIf v 1 212 ), with only the operation signatures, and a class (ForwardingDevice v 1 214 ), with both attributes and implementation methods for those operation signatures.
[0073] The reason the meta model compiler creates the interface class is to ensure that existing programs can continue to run with new revisions of a class. The one rule that makes this work is never remove methods. If the service provider makes an operation accessible it cannot retract that operation. If the service provider were to retract an operation it could cause existing programs to misbehave.
[0074] In the top-level-class case, the meta model compiler simply generates the ForwardingDeviceIf_v 1 interface 212 , and generates the ForwardingDevice_v 1 class 214 to implement that interface 212 .
[0075] In the mid-level-class case, the meta model compiler generates the IpForwarderIf_v 1 interface 222 , and generates the IpForwarder_v 1 class 224 to both (1) implement that interface 222 and (2) inherit, via inheritance relationship 226 , from the ForwardingDevice_v 1 class 214 .
[0076] [0076]FIG. 3 illustrates the consequences of a bottom-level class addition. As in the previous example of FIG. 2, creating a CiscoIpForwarderExample class 330 creates an interface 332 and a class 334 that implements it. It also creates the inheritance relationship 336 with IpForwarder class 224 .
[0077] [0077]FIG. 4 illustrates the consequences of a class change. In this example, when someone changes the IpForwarder class 220 ′ (and hence changes IpForwarderIf_v 1 interface 222 and IpForwarder_v 1 class 224 to generate IpForwarderIf_v 2 interface 422 , IpForwarder_v 2 class 424 and inheritance relationships 426 , 428 ), it causes changes below it. The meta model compiler must create new versions of all of the child classes that inherit from a changed parent class so the children pick up the changes to the parent. The meta model compiler recurses down the tree until all the child classes (i.e., CiscoIpForwarderExample class 330 ) have new versions. In addition, the meta model compiler must make the new version of each interface class inherit the interface of the previous version. As the meta model compiler recurses down the tree, it ensures that all the child interfaces, CiscoIpForwarderExampleIf interface 332 have new versions (i.e., v 2 ) 432 that inherit 438 from the old version (i.e., v 1 ) 332 . Note that the second and subsequent versions of an interface inherit from both the interface above them in the tree and the previous version of the interface. Sometimes inheriting from the interface above is redundant, but doing so reduces code complexity.
[0078] A second, and preferred embodiment of the class versioning of the present invention and instance transitioning is shown in FIGS. 5 A-D. This second scheme also shows a typical scenario, which is not meant to cover all the cases of the present invention.
[0079] [0079]FIG. 5A illustrates the first step in which Router v 1 510 is created, committed, and deployed. An instance Router# 1 512 is created and the links 514 to Router# 1 are added. Note that in this embodiment, the class name generated by the meta model compiler 511 does not contain any version information and that the generated class contains a static attribute of the class version. The instance contains an instance Vid, of which it is created. In a preferred embodiment, the present invention again uses a persistent storage database 516 with the POET SQL Object Factory or “FastObjects” object oriented database mapping software available from POET Software of San Mateo, Calif.
[0080] [0080]FIG. 5B illustrates the second step. Here, Router v 2 520 is created, committed by meta model compiler 511 , and deployed. Router# 1 is then transitioned 522 . Before transitioning, versionId in Router# 1 is “1”. After transitioning, it is set to “2”. When transitioning to a committed type, no new instance is created. When transitioning an instance, no link 514 is transitioned.
[0081] The third step is illustrated in FIG. 5C, wherein Router v 3 530 is created, compiled, and deployed. Router# 1 is transitioned 532 . When transitioning to a compiled type, a backup instance 538 is created to save the previous attribute values. After transitioning, versionId of Router# 1 is set to “3”, which is the latest version of that class.
[0082] The final step is illustrated in FIG. 5D, wherein Router v 3 is rolled back (to Router v 2 522 ). When rolling back Router v 3 , Router# 1 is restored from the backup instance 538 . Its versionId is set back to “2”. After rollback, the backup instance 538 is removed and the v 2 Router class is available to the running system. If links 514 are modified by the user after transition to a COMPILED (as opposed to commited) type, the original set of links can not be rolled back.
[0083] This second embodiment of FIGS. 5 A-D differs from the first embodiment disclosed in FIG. 1A- 1 D in the following four aspects:
[0084] First, it uses implicit class versioning, which does not create new persistence Java class for each new version. Instead, it keeps the same Java class name. It maintains static information of latest version of the class, and maintains an internal versionId in each instance.
[0085] Second, it uses alternate class hierarchy mapping options provided by POET RSMAP utility to significantly reduce the size of “polymorphic” views so that the system can support far more types. The system will apply STORE ALL option (hard-coded) to all the direct subclasses. Therefore, the following “polymorphic” views will be created:
[0086] At a privileged resource root level, a “polymorphic” view includes all the direct subclasses. Since the system does not allow user to subtype directly, the size of this view should not grow out of control.
[0087] Since STORE ALL option is applied to all direct subclasses of the privileged resource root level, no “polymorphic” view is created for those classes
[0088] “Polymorphic” views will be created for each non-leaf class. Potentially, when the individual class hierarchies grow too big (deep or/and wide), the system may run into the same problem as the one found in the first embodiment. If that is the case, the system can apply additional STORE ALL or STORE UNIVERSAL mapping option at a lower level of a particular inheritance hierarchy.
[0089] Third, the system uses POET class versioning and instance transitioning capability (RSMAP-v) to provide the backend storage changes. However, POET class versioning and instance transitioning is too simple. It only adds columns in relational database tables to reflect changes of class attributes (add, delete, or rename). The system still needs to apply its own instance transitioning capability on the top of POET so that customers can introduce more complicated transitioning logic. The system transitions instances based on the internal versionId, and the latest version of that class. As such, the system needs to maintain the same readLock( ) and writeLock( ) semantics in the first embodiment.
[0090] And finally, since the system uses implicit class versioning, it does not need to run “TypeFilter” any more.
[0091] The advantages of this preferred second embodiment of the versioning and transitioning scheme are: (i) uses simpler and less code, therefore it should be more reliable and introduce fewer bugs; (ii) creates much fewer classes and instances in the system so that it improves overall performance; (iii) provides better runtime performance since it does not need to always follow “pointers” to get the latest version of the instance; (iv) supports “unlimited” number of versions of each type; and (v) simplifies other applications, which interface with the system, such as RMI client.
[0092] Certain assumptions are associated with this embodiment. It transitions instances whenever it touches them. Since it transitions instances whenever it touches them, applications should always commit the transaction. Rollback should only be called when error occurs. Applications should only hold short transactions. In case of large result sets in a query, the present invention preferably implements a mechanism to allow users to iterate through the query over multiple short transactions. The system needs to backup transitioned instances to support “rollback” for non-committed types only to simplify testing. However, in the production system, it does not need to support instance backup and rollback since the user should not deploy a non-committed type. The user is no longer able to create instances of old versions of a type.
[0093] [0093]FIG. 6 illustrates the consequences of top-level and mid-level class additions in the second embodiment of the present invention. When a user creates the classes ForwardingDevice 610 and IpForwarder 620 , the meta model compiler will generate two classes for each user-visible class:
[0094] an interface class (ForwardingDeviceIf 612 ), with only the operation signatures, and
[0095] a class (ForwardingDevice 614 ), with both attributes and implementation methods for those operation signatures.
[0096] Again, the reason the meta model compiler creates the interface class is to ensure that existing programs can continue to run with new revisions of a class. The one rule that makes this work is never remove methods. If the service provider makes an operation accessible it cannot retract that operation. If the service provider were to retract an operation it could cause existing programs to misbehave.
[0097] In the top-level-class case, the meta model compiler simply generates the ForwardingDeviceIf interface 612 , and generates the ForwardingDevice class 614 to implement that interface 612 .
[0098] In the mid-level-class case, the meta model compiler generates the IpForwarderIf interface 622 , and generates the IpForwarder class 624 to both (1) implement that interface 622 and (2) inherit, via inheritance relationship 626 , from the ForwardingDevice class 614 .
[0099] [0099]FIG. 7 illustrates the consequences of a bottom-level class addition in the second embodiment of the present invention. As in the previous example of FIG. 6, creating a CiscoIpForwarderExample class 730 creates an interface 732 and a class 734 that implements it. It also creates the inheritance relationship 736 with IpForwarder class 624 .
[0100] [0100]FIG. 8 illustrates the consequences of a class change in the second embodiment of the present invention. In this example, when someone changes the IpForwarder class 620 ′ (and hence changes IpForwarderIf interface 622 and IpForwarder class 624 , it causes changes below it. The meta model compiler must create new versions of all of the child classes that inherit from a changed parent class so the children pick up the changes to the parent. The meta model compiler recurses down the tree until all the child classes (i.e., CiscoIpForwarderExample class 730 ) have new versions. In addition, the meta model compiler must make the new version of each interface class inherit the interface of the previous version. As the meta model compiler recurses down the tree, it ensures that all the child interfaces, CiscoIpForwarderExampleIf interface 732 have new versions 832 that inherit 838 from the old version 732 . Note that the second and subsequent versions of an interface inherit from both the interface above them in the tree and the previous version of the interface. Sometimes inheriting from the interface above is redundant, but doing so reduces code complexity.
[0101] Using either embodiment of the present invention, an organization can obtain a unified view of customers, services and networks, understand the relationships among key business data, represent complex IP services, obtain a pre-built core model of networks, services and rules for easy customization, access integrated data at multiple levels of abstractions to solve a variety of business problems, allow easy adaptation to business dynamics and obtain superior data integrity at substantial cost savings over existing systems.
[0102] Although described herein with reference to an ISP, the present invention is not so limited and has utility to other applications, including, but not limited to, health care, hotel-motel management, genome mapping, military and homeland security applications.
[0103] It will be understood by those skilled in the art that these advantages and functions are not meant as limiting but are examples of the functions and advantages of the present invention. | The present invention generally relates to object-oriented programming and more specifically relates to creating an environment where an application server may continue running while its owner makes various kinds of changes to it by employing a versioning architecture for managing version changes for classes in object-oriented environments. In a first embodiment, the system uses an explicit versioning scheme, whereas a second embodiment employs implicit versioning. In both systems, subsequent versions are created, compiled and deployed “on-the-fly” such that subsequent versions of the object class inherit all attributes, associations and operations from prior versions of the object, and wherein all versions of the object class are deployed by mapping each class into a persistence storage means. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a mobile communication network and, in particular, to a method for assigning and registering with a GAN controller appropriate for the location of the UE on the move within the mobile communication network. That is, the present invention allows the UE to re-register with a GAN controller covering the area where the UE is currently located without involvement of the user when a UE moves out of the service area of the GAN (Generic Access Network) controller within the EPS (Evolved Packet System) network providing voice services with GAN.
[0003] 2. Description of the Related Art
[0004] GAN (generic access network) is a system which is conventionally referred to as UMA (unlicensed mobile access) network. The system supports seamless handover between a cellular network and an IP access network while the UE are transmitting any, both, or nothing of voice and data. That is, the GAN system allows the mobile phone user to take advantages of the fixed broadband network.
[0005] The GAN system is an architecture component of the GERAN/UTRAN network and includes a GAN controller. The GAN controller is identical with the base station controller (BSC) of a legacy network in functional view. However, the GAN controller differs from the legacy base station controller in that it is connected to an IP access network at its front end and communicates with the UE via the interface (referred to as Up interface) using dedicated protocol for GAN. The GAN controller is responsible for converting the Up interface messaging to legacy BSC/core network interface protocol for supporting signaling and data communication between UE and network.
[0006] FIG. 1 is a diagram illustrating a mobile communication network including the PS (Packet Switched) domain with the GAN controller (Generic Access Network Controller, GANC) and the CS (Circuit Switched) domain with Mobile Switching Center (MSC).
[0007] In FIG. 1 , the User Equipment (hereinafter, referred to as UE) accesses the voice call service of the Internet Protocol (hereinafter, referred to as IP) network.
[0008] Reference numbers 101 , 103 , and 105 denote the Core Network (Non-Access Stratum) and the Access Network (Access Stratum) evolved from GPRS/UMTS (General Packet Radio Service/Universal Mobile Telecommunications System) as European 2.5 and 3 rd generation mobile communication standards.
[0009] The enhanced Node B (hereinafter, referred to as eNB) 101 manages radio access.
[0010] The Mobility Management Entity (hereinafter, referred to as MME) 103 is responsible for authentication and registration of the UE 110 which attempts to connect to the mobile communication network, processing service request from the UE 110 , and guaranteeing the mobility of the UE 110 between eNBs 101 .
[0011] The Serving Gateway (hereinafter, referred to as SGW) 105 provides the bearer service for transferring the user's service data such as voice information to the eNB 101 .
[0012] The Packet Data Network Gateway (hereinafter, referred to as PDN GW) 105 assigns an IP address to the UE 110 connected to the mobile communication network and provides IP Connectivity. In the IP network, the PDN GW 105 operates in the same way as IP router.
[0013] The SGSN (Serving GPRS Service Node) (not shown) is responsible for authentication and registration of the UE 110 which attempts to connect to the mobile communication network via a GERAN/UTRAN, processing the service request from the UE 110 , and guaranteeing the mobility of the UE 110 which moves between BSs or NodeBs.
[0014] The Mobile Switching Center (hereinafter, referred to as MSC) 115 is a switchboard providing the UE with circuit switching call processing, mobility management, and GSM service. Here, the service includes all of voice, data, FAX, and SMS.
[0015] The Home Subscriber Server (hereinafter, HSS) 109 stores the subscription information and authentication information of the subscriber and retains the address of the MCS 115 , SGSN, or MME 103 with which the subscriber is registered in the mobile communication network.
[0016] The GAN controller 117 is a device which converts signaling such that the UE can communicate with the mobile communication network via an IP access network rather than the cellular network. The GAN controller 117 is identical with the Base Station Controller (hereinafter, referred to as BSC) of the legacy GERAN network or the Radio Network Controller (hereinafter, referred to as RNC) of the UTRAN network in functional view. However, the GAN controller 117 differs from the BSC/RNC in that the GANC is connected to the UE via IP access network and can communicates with the UE using the dedicated protocol for GAN.
[0017] Although the GAN controller 117 is applied to the representative IP access network such as wireless LAN or WiFi, FIG. 1 shows the case where the Evolved Packet System (hereinafter, referred to as EPS) including eNB 101 , MME 103 , and S-GW/P-GW 105 .
[0018] The GAN controller 117 includes a Security Gateway (hereinafter, referred to as SEGW) for providing decoded communication channel in order to maintain communication security between the UE 110 and GAN controller 117 .
[0019] FIG. 2 is a diagram illustrating signaling of the procedure for registration and deregistration of the UE with the GAN controller 117 when the UE moves in or out a GAN service area.
[0020] The UE 110 enters the service area of the GAN controller 117 at step 201 . The UE 110 makes a query to the DNS server for the IP address of the SEGW 119 for establishing a secure IP tunnel with the SEGW 119 and acquires the IP address at step 203 . Next, the UE 110 establishes the secure IP tunnel with the SEGW 119 with the IP address of the SEGW 110 at step 205 . Next, the UE 110 acquires the IP address of the GAN controller 117 from the DNS server of the GAN via the secure IP tunnel established with the SEGW 119 at step 207 .
[0021] The UE 110 sends a GAN registration request message (hereinafter, interchangeably used with the term “GA-RC REGISTER REQUEST message”) to the IP address of the GAN controller 117 so as to request for the GAN service registration at step 209 . The GAN registration request message includes a CID (Cell ID), a LAI (Location Area Id), and an IMSI (International Mobile Subscriber Identity).
[0022] The GAN controller 117 which has received the GAN registration request message from the UE sends a GAN registration accept message (hereinafter, interchangeably used with the term “GA-RC REGISTER ACCEPT message) to the UE to notify of the completion of the GAN service registration at step 211 . At this time, the GA-RE REGISTER ACCEPT message includes the system information of the GAN.
[0023] After the completion of the GAN service registration, the UE 110 initiates the Location Area Update process by sending a Location Area Update request message to the MSC 115 via the GAN controller 117 at step 213 . Afterward, the incoming call received by the MSC 115 is sent to the UE 110 via the GAN controller 117 .
[0024] If the UE 110 moves out of the service area of the GAN controller 117 , the UE 110 sends a GAN Deregistration message (hereinafter, interchangeably used with the term “GA-RC DEREGISTER message”) to the GAN controller 117 for GAN deregistration at step 217 . Once the GSN service is deregistered, the UE 110 initiates Location Area Update process by sending a Location Area Update request message to the MSC via the BSS or RNS for receive an incoming call directly from the MSC 115 by means of A or Iu message of the BSS or RNS at step 219 . Afterward, the UE 110 receives the incoming call sent by the MSC 115 via the BSS or RNS.
[0025] In case that the GAN service is provided by means of wireless LAN, the GAN service area is confined by the area centering around an access point such that the GAN service is provided within a Hot Zone. Accordingly, when the UE moves out of the Hot Zone, the GAN service is deregistered according to the steps following step 215 of FIG. 2 ; and when the UE moves in another Hot Zone, the GAN service registration procedure is initiated from the first step. As a consequence, there is no need for the UE 110 to roam between Hot Zones while maintaining the GAN service registration, and the UE switches between GAN controllers as roaming from one to another Hot Zone.
SUMMARY OF THE INVENTION
Problem to be Solved
[0026] The present invention provides a method and apparatus for maintaining registration with a GAN controller appropriate for the location of the UE in the mobile communication network supporting voice services by means of GAN service especially when the UE registered with a GAN controller moves to an EPS network in a LTE area.
Means for Solving the Problem
[0027] In order to solve the above problems, a method for changing GAN controller in a mobile communication network supporting GAN (Generic Access Network) terminal includes transmitting, a location change of the terminal is detected, a Location Area Update Request (LAU Request) message from the terminal to a GAN controller with which the terminal is registered; determining, at the GAN controller, whether the terminal is necessary to change the GAN controller; and transmitting, when the terminal is necessary to change the GAN controller, a GAN control registration change indication message (GA-RC REGISTER REDIRECT) from the GAN controller to the terminal.
[0028] In accordance with another aspect of the present invention, a method for changing GAN controller in a mobile communication system supporting GAN (Generic Access Network) terminal includes instructing, at a mobility management entity when change of location of a terminal is detected, the terminal to relocate the GAN controller (GANG relocation Required); requesting, at the terminal, the GAN controller with which the terminal is registered for GAN registration update (GA-RC REGISTER UPDATE UPLINK); and transmitting, when the request is received, information on a new GAN controller from the registered GAN controller to the terminal.
[0029] In accordance with still another aspect of the present invention, a method for changing GAN controller in a mobile communication network supporting GAN (Generic Access Network) terminal includes transmitting, when a mobility management entity detects change of location area of the terminal, a Location Area (LA) change of the terminal to a GAN controller with which the terminal is registered; determining, at the GAN controller, whether the terminal is necessary to change GAN controller; and transmitting, when the terminal is necessary to change GAN controller, a GAN controller registration change instruction (GA-RC REGISTER REDRICT) message from the GAN controller to the terminal.
Advantageous Effects
[0030] According to the present invention, the UE receiving the voice call service with the GAN controller in an LTE service area can receive the incoming call, without notifying the mobile communication network of the current location, when the UE crosses between LTE service area and WCDMA/GSM service area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a diagram illustrating a communication network including a PS domain with a GAN controller and a CS domain with a Mobile Switching Center (MCS).
[0032] FIG. 2 is a diagram illustrating signaling of the procedure for registration and deregistration of the UE with the GAN controller 117 when the UE moves in or out a GAN service area.
[0033] FIG. 3 is a diagram illustrating signaling for registering the UE with a new GAN controller according to the first embodiment of the present invention.
[0034] FIG. 4 is a diagram illustrating signaling for registering the UE with a new GAN controller according to the second embodiment of the present invention.
[0035] FIG. 5 is a diagram illustrating signaling for registering the UE with a new GAN controller according to the third embodiment of the present invention.
[0036] FIG. 6 is a flowchart illustrating operations for the MME to instruct the UE for GAN controller re-registration request according to the first embodiment of the present invention.
[0037] FIG. 7 is a flowchart illustrating operations for the MME to instruct the UE for GAN controller re-registration request according to the second embodiment of the present invention.
[0038] FIG. 8 is a flowchart illustrating operations for the MME to instruct the UE for GAN controller re-registration request according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0039] Exemplary embodiments of the present invention are described with reference to the accompanying drawings in detail. Detailed description of well-known functions and structures incorporated herein may be omitted to avoid obscuring the subject matter of the present invention. The following terms are defined in consideration of functions in the present invention, and the meanings thereof may vary according to the intention of a user or an operator or according to usual practice. Therefore, the definitions of the terms must be interpreted based on the entire content of the present specification.
[0040] Although the description is directed to the embodiments of the present invention with an exemplary case of EPS (Evolved Packet System) core network as the core network evolved based on the 3GPP, the procedure for providing the GAN service in the present invention can be applied to any type of mobile communication networks in the same manner.
[0041] In the following, the description is made of the first to third embodiments differentiated by the method for a UE to register with a new GAN controller. FIGS. 3 and 6 are the drawings for illuminating the first embodiment, FIGS. 4 and 6 for illuminating the second embodiment, and FIGS. 5 and 8 for illustrating the third embodiment.
[0042] FIG. 3 is a diagram illustrating signaling for registering the UE 110 with a new GAN controller when the UE 110 registered with a certain GAN controller 310 moves into the service area of an EPS core network and registers its current location with the EPS core network, while moving out of the service area of the current GAN controller 117 , according to the first embodiment of the present invention.
[0043] The UE 110 moves into a new tracking area (hereinafter, referred to as TA) which is not included in the registered Tracking Area List (hereinafter, referred to as TA list) at step 301 of FIG. 3 . The UE 110 sends a Tracking Area Update request message to request the MME 103 for registering the new location.
[0044] The MME 103 processes the location registration request of the UE 110 and replies by sending a Tracking Area Update Accept message to the UE 110 at step 303 .
[0045] The MME 103 determines that the UE 103 registered with a certain GAN 310 moves out of the service area of the currently registered GAN controller 310 at step 305 . Here, the MME 103 sends the UE 110 a S 1 connection release message with the cause of GAN controller Relocation Required (hereinafter, interchangeably used with the term “GANC Relocation Required”) to request the UE 110 for GAN registration.
[0046] For example, the MME 103 manages the mappings between the TA of the UE 110 and the Location Area (hereinafter, referred to as LA) such that, when the UE 110 moves out of the LA served by the GAN controller 310 , the MME 103 determines the registration of the UE 110 with a new GAN controller 320 .
[0047] The eNB 101 sets the cause of the RRC connection release message to “GANC relocation required” so as to notify the UE 110 of the necessity of switching of the GAN controller 310 , at step 307 .
[0048] In order to update the GAN controller registration, the UE 110 sends a Service Request message to the GAN controller 310 to establish a radio bearer for transmitting data and transitions to the active state, at step 308 .
[0049] The UE 110 sends a GAN registration update uplink message (hereinafter, interchangeably used with the term “GA-RC REGISTER UPDATE UPLINK message”) to the old GAN controller 310 with which the UE is currently registered in order to request for the GAN registration update at step 309 . In this case, the UE transmits the LAI (Location Area Identifier) as its location identifier in the GAN registration update uplink message. The old GANC 310 identifies the current location of the UE 110 based on the LAI transmitted by the UE 110 and determines registration with a new GAN controller 320 , at step 311 .
[0050] Next, the old GAN controller 310 sends a GAN registration reconfiguration message (hereinafter, interchangeably used with the term “GA-RC REGISTER REDIRECT message”) containing the information on the new GAN controller 320 to the UE 110 . Here, the information on the new GAN controller 320 includes the IP address of the new GAN controller 320 .
[0051] The UE 110 receives the information on the new GAN controller 320 from the old GAN controller 310 at step 311 and establishes a secure tunnel for secure communication with the new GAN controller 320 at step 313 . According to an embodiment of the present invention, the secure tunnel can be an IPSec tunnel as an example.
[0052] The UE 110 transmits the GA-RC REGISTER REQUEST message to the new GAN controller 320 via the secure tunnel (established at step 313 ) to requests for registration with the new GAN controller 320 at step 315 . The new GAN controller 320 processes the GAN registration request message of the UE 110 at step 317 . The GAN registration is successful, the UE 110 requests the MSC 115 for location registration via the new GAN controller 320 at step 319 .
[0053] FIG. 4 is a diagram illustrating signaling for registering the UE 110 with a new GAN controller when the UE 110 registered with a certain GAN controller moves into the service area of an EPS core network and registers the current location of the UE 110 with the EPS core network, while moving out of the service area of the current GAN controller, according to the second embodiment of the present invention.
[0054] As the UE 110 moves into a new TA which is not included in the registered TA list (Tracking Area List), it sends the Tracking Area Update request to MME 103 for new location registration at step 401 . The MME 103 processes the location registration request from the UE 110 and replies by sending a Tracking Area Update Accept message to the UE 110 . At this time, the MME 103 sends the LA identity information (LAI) corresponding to the TA in which the UE 110 is located using the information on the mappings between TA and LA which is managed by the MME 103 .
[0055] The UE 110 receives the LAI transmitted by the MME 103 and compares the received LAI with the LAI received from the GAN controller 310 with which the UE 110 has been registered previously, at step 403 .
[0056] In case that the two LAIs differ from each other, the UE 110 establishes a radio bearer for transmitting the Location Area Update Request message (LAU request message) to request for the location registration update of the MSC 115 , at step 405 .
[0057] The UE 110 sends the LAU request message to the GAN controller 310 with which the UE 110 is previously registered, at step 407 . Upon receipt of the LAU request message, the GAN controller 310 checks that the UE 110 is currently located out of the its service area and determines the necessity of the GAN controller switching. The GAN controller 310 sends the GA0RC REGISTER REDIRECT message to the UE 110 to instruct to switch to the new GAN controller 320 . The GA-RC REGISTR REDIRECT message includes the information on the IP address of the new GAN controller 320 .
[0058] The UE 110 receives the information on the new GAN controller 320 from the old GAN controller 310 at step 409 and establishes a secure tunnel for security communication with the new GAN controller 320 at step 411 .
[0059] The UE 110 sends the GA-RC REGISTER REQUEST message to the new GAN controller 320 via the secure tunnel established at the previous step to request for the new registration at step 413 . The new GAN controller 320 processes the new registration of the UE 110 at step 415 . If the new registration is successful, the UE 110 requests the MSC 115 for the location registration again via the new GAN controller 320 .
[0060] FIG. 5 is a diagram illustrating signaling for registering the UE 110 with a new GAN controller when the UE 110 registered with a certain GAN controller moves into the service area of an EPS core network and registers the current location of the UE 110 with the EPS core network, while moving out of the service area of the current GAN controller, according to the third embodiment of the present invention.
[0061] The UE 110 moves into a new TA which is not included in the registered TA list at step 501 of FIG. 5 . In this case, the UE 110 sends the Tracking Area Update request to the MME 103 .
[0062] Next, the MME 103 determines whether the UE 110 is registered with a certain GAN controller. If the UE 110 is registered with a GAN controller, the MME 103 detects the change of the LA where the UE 110 is located using the mapping information between TA and LA under its management and notifies a certain GAN controller 310 of the LA change by sending the Location Area Change message (LA change message) at step 503 . At this time, the LA change message includes the LAI acquired by mapping the IMSI (Internal Mobile Subscriber Identity) as the identifier of the UE 110 and TA.
[0063] The GAN controller 310 replies by transmitting the location area change ask (LA check ask) message to the MME 103 at step 505 .
[0064] After completing the location registration of the UE 110 , the MME 103 replies by sending the TAU accept message to the UE 110 at step 507 .
[0065] Meanwhile, the GAN controller 310 receives the LAI information of the UE 110 from the MME and determines that the UE 110 is out of its service area, at step 503 . The GAN controller 310 sends the GA-RC REGISTER REDIRECT message to the UE 110 to instruct the UE 110 to update the GAN registration with the new GAN controller 320 at step 509 . The GA-RC REGISTER REDRICT message includes the information on the IP address of the new GAN controller 320 .
[0066] The UE 110 receives the information on the GAN controller from the old GAN controller 310 at step 509 and establishes a secure tunnel for secure communication with the new GAN controller 320 .
[0067] The UE 110 sends the GA-RC REGISTER REQUEST message to the new GAN controller 320 via the secure tunnel established at the previous step in order to request for new registration at step 513 . The new GAN controller 320 processes the new registration request of the UE 110 at step 515 . If the new registration is successful, the UE 110 requests the MSC 115 for location registration again via the new GAN controller 320 at step 517 .
[0068] FIG. 6 is a flowchart illustrating operations for the MME to instruct the UE for the GAN controller re-registration request when the UE registered with a certain GAN controller transmits the TAU request message to the MME, according to the first embodiment of the present invention.
[0069] Referring to FIG. 6 , the MME 103 receives the TAU request form the UE 110 at step 601 . Upon receipt of the TAU request, the MME 103 processes the TAU request at step 603 and sends the UE 110 the TAU response message at step 605 .
[0070] Next, the MME 103 checks whether the UE 110 is registered with the GAN at step 607 and checks the LA from the current TA of the UE when the UE 110 is registered with the GAN. Next, the MME 103 checks whether the LA is included in the service area of the GAN controller 310 with which the UE is currently registered. The MME 103 can determine whether the checked LA is included in the service area of the GAN controller 310 by using the mapping relationship between the TA of the UE 110 and the LA.
[0071] If the LA is included in the service area of the GAN controller 310 or changed, the MME 103 sets the SI connection release cause to GANC relocation request so as to instruct the UE 110 to reconfigure the GAB registration via the RRC release cause at step 611 . The MME 103 releases the S 1 connection at step 613 . Accordingly, the UE 110 can perform registration with the new GAN controller 320 according to the following procedure.
[0072] FIG. 7 is a flowchart illustrating operations for the MME to notify the UE of the current LA in response to the TAU request message transmitted by the UE according to the second embodiment of the present invention.
[0073] Referring to FIG. 7 , the MME 103 receives the TAU request from the UE 110 at step 701 and processes the TAU request at step 703 . Next, the MME 103 determines whether the UE 110 is registered with a certain GAN, at step 705 . If the UE is registered with a specific GAN, the MME 103 checks the LA using the current TA of the UE and generates the LAI as the location area identifier of the current location of the UE 110 at step 707 . Next, the MME 103 adds the generated LAI to the TAU accept response message. The MME 103 sends the TAU accept message to the UE 110 at step 709 . The UE 110 can perform registration with the new GAN controller 320 based on the information carried in the TAU accept message.
[0074] FIG. 8 is a flowchart illustrating operations for the MME to instruct the UE to perform GAN re-registration by notifying the GAN controller of the change of the LA of the UE when the UE registered with a certain GAN controller has sent the TAU request message to the MME, according to the third embodiment of the present invention.
[0075] Referring to FIG. 8 , the MME 103 receives the TAU request from the UE 110 at step 801 and processes the TAU request at step 803 . The MME 103 determines whether the UE 110 is registered with a GAN, at step 805 . If the UE 110 is registered with a GAN, the MME 103 checks the LA from the LA of the UE 110 to determine whether the LA is changed, at step 807 . If the LA is changed, the MME 103 sends a LA change message to the GAN controller 301 with which the UE 110 is currently registered. If an LA change acknowledgement message is received from the GAN controller 310 in response to the LA change message, the MME 103 sends a TAU accept response message to the UE 110 at step 811 . The UE 110 can perform the procedure for registration with the new GAN controller 320 based on the TAU accept response message afterward.
[0076] The embodiments disclosed in the specification and drawings aim only to help understand but not limit the present invention. Meanwhile, persons ordinarily skilled in the art would make modifications in terms of specific embodiments and application scopes without departing from the concepts of the present invention. | The present invention relates to a mobile communication network, and more particularly to a method for the allocation and registration of a suitable generic access network (GAN) controller for the location of a terminal when the terminal moves in the mobile communication network. The mobile communication network comprises: a terminal, which transmits the location information thereof to the mobile communication network, makes a new request for GAN controller information under instructions from the mobile communication network and performs GAN registration again based on the GAN controller information provided from the mobile communication network; a mobility management entity, which receives a location registration request from the terminal, changes WCDMA/GSM location information from the location information of the terminal in the current LTE service area and sends the changed information to the terminal, instructs the terminal to do GAN re-registration and notifies the GAN controller of the change in the location information of the terminal; and the GAN controller, which processes the GAN registration from the terminal and assigns suitable GAN control information for the current location of the terminal. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates generally to skid steer loaders having an implement mounting mechanism adaptable for selectively mounting a variety of implements thereto and, more particularly, to an adaptor mechanism for use with the skid steer loader implement mounting mechanism to permit an implement of a different attachment configuration to be mounted to the skid steer loader and used therewith.
Skid steer loaders are typically provided with a unitized frame having fixed wheels mobilely supporting the frame over the ground. The wheels are driven hydraulically in a manner that differential power can be applied to the wheels on the opposing sides of the loader to effect a steering thereof in a skidding manner somewhat like a tank. Skid steer loaders have a centrally located operator compartment and boom arms pivotally mounted to the frame and extending forwardly of the loader to carry an implement mounting mechanism which is engageable with detachable implements positionable within the view of the operator to permit a variety of uses of the skid steer loader. These implement mounting mechanisms utilize a quick-attach apparatus to facilitate the mounting of an implement thereto.
Skid steer loaders built by one manufacturer will normally utilize a different quick-attach apparatus configuration than each of the competitive companies. As a result, implements are typically not interchangeable between skid steer loaders of one manufacturer and those of another. Since implements do not necessarily require replacement at the same frequency which the skid steer loader requires replacement, an operator may be financially restrained from purchasing either the implements or the skid steer loader from more than one particular manufacturer to remain consistent in the mounting mechanisms being utilized This problem could be alleviated if an adaptor mechanism were provided to permit the implements manufactured by one manufacturer to be mounted to the skid steer loader of a different manufacturer, even though the manufacturers are utilizing different attachment configurations.
SUMMARY OF THE INVENTION
It is an object of this invention to overcome the aforementioned disadvantages of the prior art by providing an adaptor mechanism for use with skid steer loaders to permit the attachment of implements thereto even though utilizing a different attachment configuration.
It is another object of this invention to provide an adaptor mechanism that can be mounted on the skid steer loader of one manufacturer to permit the selective attachment of implements of a second manufacturer.
It is an advantage of this invention that an operator of a skid steer loader can have greater flexibility in the selection of implements to be mounted on the skid steer loader for use therewith.
It is a feature of this invention that the adaptor mechanism incorporates the attachment configuration of both the skid steer loader and the implements to be attached thereto.
It is another advantage of this invention that the implements utilizing one attachment configuration can be mounted on a skid steer loader utilizing a second attachment configuration.
It is another feature of this invention that the overcenter wedging mechanism associated with the skid steer loader of one manufacturer can be utilized in the same manner to attach implements thereto irrespective of the manufacturer of the implement.
It is still another feature of this invention that the adaptor mechanism utilizes a locking mechanism movable between a retracted position and an engaging position.
It is still another advantage of this invention that the engagement of hook members on the adaptor mechanism by the skid steer loader overcenter wedging mechanism forces locking pins into engagement with an implement to effect a mounting thereof to the adaptor mechanism.
It is yet another feature of this invention that the adaptor mechanism incorporates a spring biasing the locking mechanism into a retracted position.
It is yet another advantage of this invention that the mounting of the adaptor mechanism to the implement mounting apparatus of the skid steer loader causes a partial deflection of the biasing spring to urge hook members into engagement with the implement mounting apparatus to retain the adaptor mechanism on the skid steer loader.
It is still another object of this invention to provide an adaptor mechanism utilizing first and second attachment configurations interengaged with one another to permit the manipulation of the attachment configuration associated with the skid steer loader to effect a mounting of an implement utilizing a different attachment configuration.
It is a further object of this invention to provide an adaptor mechanism for use with a skid steer loader which is durable in construction, inexpensive of manufacture, carefree of maintenance, facile in assemblage, and simple and effective in use.
These and other objects, features and advantages are accomplished according to the instant invention by providing an adaptor mechanism for use with a skid steer loader having an implement mounting plate configured in a first attachment configuration, wherein the adaptor mechanism permits the attachment of an implement configured in a second implement attachment configuration to the skid steer loader. The adaptor mechanism includes a movable locking mechanism having hook members protruding perpendicularly therefrom for engagement with the overcenter wedging mechanism in the implement mounting apparatus on the skid steer loader. A spring biases a locking mechanism toward a retracted position; however, engagement of the hook members by the skid steer loader overcenter wedging mechanism overcomes the biasing force exerted by the spring to force the locking mechanism into engagement with the implement being mounted thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of this invention will become apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1a is a partial cross-sectional view of a skid steer loader taken along lines 1a-1a of FIG. 1b to depict a partial side elevational view of a skid steer loader of known construction approaching an implement having the same attachment configuration to effect the mounting thereof on the skid steer loader;
FIG. 1b is a partial top plan view of the skid steer loader and implement shown in FIG. 1a;
FIG. 2a is a partial cross-sectional view of a skid steer loader taken along lines 2a-2a of FIG. 2b to depict a partial side elevational view of the skid steer loader corresponding to that of FIG. 1a with the detachable implement being mounted thereon;
FIG. 2b is a partial top plan view of the skid steer loader and mounted implement shown in FIG. 2a;
FIG. 3a is a partial cross-sectional view corresponding to that of FIG. 1a and schematically depicting a side elevational view of the adaptor mechanism to permit the mounting of an implement utilizing a different attachment configuration on the skid steer loader;
FIG. 3b is a partial top plan view of the skid steer loader, implement, and adaptor mechanism shown in FIG. 3a;
FIG. 4 is a rear elevational view of the adaptor mechanism corresponding to lines 4--4 of FIG. 3a;
FIG. 5 is a top plan view of the adaptor mechanism shown in FIG. 4;
FIG. 6 is a front elevational view of the adaptor mechanism to be engaged with the implement;
FIG. 7 is a cross-sectional view of the adaptor mechanism taken along lines 7--7 of FIG. 6;
FIG. 8 is a cross-sectional view similar to that of FIG. 7 but showing the adaptor mechanism mounted on the implement mounting apparatus of the skid steer loader, the implement mounting apparatus also being shown in phantom as though moving into engagement with the adaptor mechanism.
FIG. 9 is a cross sectional view similar to that of FIGS. 7 and 8 depicting an implement mounted on the adaptor mechanism, which in turn is mounted on the implement mounting apparatus of the skid steer loader, the movement of the overcenter wedging mechanism being shown in phantom;
FIG. 10 is an enlarged partial cross sectional view of the adaptor mechanism taken along lines 10--10 of FIG. 7 to show a top plan view of the movable locking mechanism; and
FIG. 11 is an enlarged partial cross sectional view of the adaptor mechanism taken along lines 11--11 of FIG. 10 to depict an elevational view of the movable locking mechanism, the movement of the locking mechanism being shown in phantom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and, particularly, to FIGS. 1 and 2 the known mounting of an implement to the implement mounting apparatus of a skid steer loader can best be seen. The skid steer loader 10 includes hydraulically driven wheels 11 mobilely supporting the skid steer loader 10 over the ground G and forwardly extending, pivoted boom arms 12 carrying at the forward ends thereof an implement mounting apparatus 15 engageable with an implement 18 to effect a mounting thereof on the skid steer loader 10.
It can be seen that both the implement mounting apparatus 15 and the implement 18 utilize identical attachment configurations in the form of a pair of rearwardly directed hook members 19 insertable through the implement mounting apparatus 15 to be engageable with an overcenter wedging mechanism 16 to detachably affix the implement 18 on the skid steer loader 10, the implement mounting apparatus -5 being wedged underneath an angled support member 17 forming a part of the implement 18. The implement mounting apparatus 15 and operation of the overcenter wedging mechanism 16 are described in greater detail in U.S. Pat. No. 3,794,195 issued to J. T. Clevenger et al on Feb. 26, 1984, the descriptive portions of which are incorporated herein by reference.
Referring now to FIGS. 3a and 3b, it can be seen that the implement 20, exemplarily shown in the form of a bucket, is provided with an attachment mechanism 22 having a different configuration than the implement 18 shown in FIGS. 1 and 2. More specifically, the attachment mechanism 22 includes a outwardly sloping member 23, which generally corresponds to the angled support member 17 of the implement 18; however, instead of hook members 19, as seen in FIGS. 1 and 2, the attachment mechanism 22 utilizes rearwardly extending brackets 24 having a generally vertical hole 25 formed therein for engagement with a locking pin (not shown) to fix the implement 20 on its corresponding loader.
One skilled in the art will readily realize that the implement mounting apparatus -5 described above with respect to FIGS. 1 and 2 and shown in FIG. 3 does not incorporate a downwardly moving locking pin to permit the implement 20 to be mounted thereon for operative use. Accordingly, the operator of the loader 10 having an implement mounting apparatus 15 of the configurations shown in FIGS. 1, 2, and 3, would not be able to use the implement 20 without the provision of an adaptor 30 disposed therebetween.
Referring now to FIGS. 3-6, the general structural features of the adaptor mechanism can best be seen. The adaptor 30 shown in FIGS. 3-11 is described herein as being configured to permit the mounting of an implement 20 having an attachment mechanism 22 on the loader 10 provided with an implement mounting apparatus 15 of the configuration utilizing hook members 19 as described above. However, one skilled in the art will readily realize that other adaptor configurations can be provided within the principles and scope of the invention to mount implements having still further attachment configurations on a loader having yet a different attachment mounting apparatus.
The adaptor 30 has a first attachment mechanism 31 configured to be mounted on the implement mounting apparatus 15 on the loader 10. The attachment mechanism 31 includes a downwardly extending angled support member 32 positioned to fit over top of the implement mounting apparatus 15 and a pair of rearwardly extending hook members 33 engageable with the overcenter wedging mechanism 16 when inserted into the implement mounting apparatus 15. The adaptor 30 also includes a second attachment mechanism 36 having an upwardly extending sloped member 37 positionable underneath the angled member 23 on the implement 20 and a pair of generally vertically movable locking pins 38 insertable through the holes 25 in the rearwardly extending bracket for the implement 20.
As best seen in FIGS. 3-6, the adaptor 30 presents an attachment mechanism 31 to the implement mounting apparatus 15 that approximates a normal engagement with a similarly configured implement 18, as shown in FIGS. 1 and 2. Accordingly, the first attachment mechanism 31 is provided with a first faceplate 34 extending downwardly from the angled support member 32 spanning the gap between the transversely spaced hook members 33. Likewise, the second attachment mechanism 36 approximates the normal implement mounting apparatus typically used in conjunction with the attachment of the implement 20 and includes a pair of second faceplates 39 corresponding to the transversely spaced locking pins 38 to engage the implement 20 and properly position the locking pins 38 for insertion through the holes 25 and bracket 24.
The structural details of the adaptor 30 are best seen in FIGS. 3 and 7-11. Each rearwardly extending hook member 33 is rigidly attached to the corresponding locking pin 38 to form a part of the locking mechanism 40 described in greater detail below. A pair of guide members 41 are affixed to the first faceplate 34 to guide the generally vertical movement of each locking mechanism 40 between the first and second faceplates 34, 39. As best seen in FIG. 11, the locking mechanism 40 is a specially formed piece having a locking pin 38 transversely offset from the hook member 33 to permit proper alignment between the implement mounting apparatus 15 and the hole 25 in the rearwardly extending bracket 24. The locking mechanism 40 also includes an upwardly extending guide portion 43 positionable between the guide members 41 to control the movement of the locking mechanism 40. As best seen in FIGS. 4 and 6, the first faceplate 34 is provided with a pair of vertically extending slotted cut-outs 44 to accommodate the vertical movement of the hook members 34 as will be described in greater detail below.
Returning now to FIGS. 3 and 7-11, it can be seen that the adaptor 30 is also provided with a pair of extension springs 45 extending between an upper mounting bracket 47 forming the upwardly sloped member 37 and the locking mechanism 40 to bias the locking mechanism 40 into an upward retracted position. To provide proper structural integrity of the second attachment mechanism 36, a pair of transversely spaced frame supports 49 are positioned on opposing sides of the springs 45 and affixed to both the first faceplate 34 and the corresponding faceplate 39 to encapsulate the generally vertically movable locking mechanism 40 and the biasing springs 45.
The operation of the adaptor 30 is best shown in FIGS. 7-9. FIG. 7 depicts the adaptor 30 in an unmounted state relative to both the loader 10 and the implement 20. The locking mechanism 40 is placed in the retracted position by the biasing force exerted thereon by the springs 45. In the retracted position, the locking pins 38 can be positioned above the corresponding holes 25 and the bracket 24 but are not engaged therewith. The hook members 33, when in the retracted position, are slightly out of alignment with the corresponding openings through the implement mounting apparatus 15, thereby requiring a slight downward movement of the locking mechanism 40 to permit the hook members 33 to pass into the implement mounting apparatus 15 for engagement with the overcenter wedging mechanism 16.
The adaptor 30 is first mounted on the implement mounting apparatus 15. The loader 10 is positioned, as shown in phantom in FIG. 8, such that the implement mounting apparatus 15 can be positioned underneath the angled support member 32. The hook members 33 are formed with a rearwardly facing cam surface 53 which is angled to cause a downward deflection of the hook members 33 when engaged against the implement mounting apparatus 15, thereby causing a sufficient downward movement of the locking mechanism 40 to align the hook members 33 with the openings in the implement mounting apparatus 15 to permit insertion thereof for a subsequent engagement with the overcenter wedging mechanism 16.
This slight downward movement of the locking mechanism 40 effects a corresponding extension of the springs 45 to increase the biasing force exerted thereby and urge the hook members 33 upwardly into engagement with the implement mounting apparatus 15. As a result, the spring 45 effectively clamps the adaptor 30 onto the implement mounting apparatus 15 between the angled support member 32 and the upwardly urged hook members 33 to retain the adaptor 30 on the implement mounting apparatus 15 without involvement of any additional fastening members. It should be noted that the locking pins 38 are oriented such that they are still positionable over the corresponding holes 25 in the rearwardly extending brackets 24 even when the adaptor 30 is mounted on the implement mounting apparatus 15.
As best seen in FIG. 9, the adaptor 30, having been mounted on the implement mounting apparatus 15, is now positionable upon proper manipulation of the loader 10 such that the upwardly sloped member 37 can be positioned underneath the angled member 23 on the implement 20. A subsequent positioning of the second faceplates 39 against the implement 20 positions the locking pins 38 above the holes 25 in the brackets 24 of the implement 20. A subsequent manipulation of the overcenter wedging mechanism 16 in the same manner described above with respect to FIGS. 1 and 2 forces the wedge 55 downwardly into an engaging position whereby the locking pins 38 are inserted into the holes 25, thereby mounting the implement 20 on the adaptor 30.
In this engaging position, the adaptor 30 is secured to the implement mounting apparatus 15 by the overcenter wedging mechanism 16 preventing the hook members 33 from withdrawing from the implement mounting apparatus 15, while the implement 20 is secured to the adaptor 30 by the locking pins 38 inserted through the holes 25 to prevent the implement 20 from pulling away from the adaptor 30. Although the springs 45 continue to exert a biasing force on the locking mechanism 40 to retract the locking mechanism from the engaging position, the biasing forces exerted by these springs 45 are overcome by the overcenter wedging mechanism 16 forcing the hook members 33 downwardly into the engaging position. Once the adaptor 30 is mounted on the implement mounting apparatus 15, a plurality of implements can be selectively mounted and dismounted in the same manner as if the implements had an identical attachment mechanism configuration as the loader 10. Accordingly, one skilled in the art will readily appreciate that the mounting of an implement 20 having an attachment mechanism 22 configured differently than the implement mounting apparatus 15 can be operatively mounted on the loader 10 by utilizing the identical overcenter wedging mechanism 16 in the same manner described relative to FIGS. 1 and 2.
Dismounting the implement 20 can be accomplished in the same manner as if the implement 20 utilized an attachment mechanism of a configuration identical to that of the loader 10. By releasing the overcenter wedging mechanism 16, the locking mechanism 40 is permitted to move back toward the retracted position by the biasing forces exerted by the springs 45. As a result, the locking pins 38 retract from the holes 25 in the rearwardly extending brackets 24 and permit the adaptor 30 to disengage from the implement 20. A subsequent re-engagement of the same implement 20 or yet another implement having an identical attachment mechanism 22 can be accomplished by engaging the upwardly sloped member 37 with the corresponding angled member 23 and re-manipulating the overcenter wedging mechanism 62 to force the locking mechanism 40 back into its engaging position.
To permit the loader 10 to mount an implement 18 having correspondingly configured attachment mechanism, it is first necessary to remove the adaptor 30 from the implement mounting apparatus 15. Once the implement 20 has been dismounted from the adaptor 30 as depicted in FIG. 8, it is necessary to overcome the biasing force exerted by the springs 45 to deflect the hook members 33 downwardly sufficiently to pass through the openings in the implement mounting apparatus 15 so that the hook members 33 disengage from the implement mounting apparatus 15, permitting the locking mechanisms 40 to return to the fully retracted position whereupon the loader 10 can be manipulated to disengage the implement mounting apparatus 15 from the angled support member 32 to effect a disconnection of the adaptor 30 from the loader 10. Accordingly, it can be seen that the skid steer loader 10 can be utilized with implements 18, 20 manufactured in a configuration identical to the implement mounting apparatus 15 or manufactured in a completely different configuration, as exemplified by the attachment mechanism 22.
It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown. | An adaptor mechanism for use with a skid steer loader having an implement mounting plate configured in a first attachment configuration is disclosed wherein the adaptor mechanism permits the attachment of an implement configured in a second implement attachment configuration to the skid steer loader. The adaptor mechanism includes a movable locking mechanism having hook members protruding perpendicularly therefrom for engagement with the overcenter wedging mechanism in the implement mounting apparatus on the skid steer loader. A spring biases a locking mechanism toward a retracted position; however, engagement of the hook members by the skid steer loader overcenter wedging mechanism overcomes the biasing force exerted by the spring to force the locking mechanism into engagement with the implement being mounted thereto. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a circuit structure of a pixel region of an active matrix type display device using thin-film transistors, and particularly to a structure of an auxiliary capacitor.
[0003] 2. Description of the Related Art
[0004] In recent years, a technique for manufacturing thin-film transistors (TFT) on an inexpensive glass substrate has been rapidly developed. The reason is that the demand for active matrix type liquid crystal display devices has been increased.
[0005] In the active matrix type liquid crystal display device, thin-film transistors are respectively arranged for each of several tens to several million pixels arranged in matrix form to control electrical charge going in and out of the respective pixel electrodes by a switching function of the thin-film transistor.
[0006] A liquid crystal is placed between the respective pixel electrodes and opposing electrodes so that a kind of capacitor is formed. Accordingly, if going in and out of electrical charge to the capacitor is controlled by the thin-film transistor, the electro-optical characteristics of the liquid crystal are changed so that a picture image can be displayed by controlling light transmitting through a liquid crystal panel.
[0007] The capacitor having such a structure has a problem that since a hold voltage of the capacitor is gradually decreased by a leak current, the electro-optical characteristics of the liquid crystal is changed so that the contrast of display of a picture image is deteriorated.
[0008] Then, such a structure becomes common that another capacitor referred to as an auxiliary capacitor is disposed in series with the capacitor constituted by the liquid crystal so that electrical charge lost through a leak or the like is supplied to the capacitor constituted by the liquid crystal.
[0009] [0009]FIG. 4 is a circuit diagram showing a conventional active matrix type liquid crystal display device. The active matrix type liquid crystal display circuit is roughly divided into three parts. That is, the circuit is divided into a gate driver circuit 62 for driving gate wiring lines (scan wiring lines) 64 , a data driver circuit 61 for driving data wiring lines (source wiring lines, signal wiring lines), and an active matrix circuit 63 in which pixels are provided. Among them, the data driver circuit 61 and the gate driver circuit 62 are generally referred to as a peripheral circuit.
[0010] In the active matrix circuit 63 , a number of gate wiring lines 64 and data wiring lines 65 are provided so as to cross with each other, and pixel electrodes 67 are provided at each intersection point. Further, a switching element (thin-film transistor) 66 for controlling electrical charge going in and out of the pixel electrode is provided. Still further, as described above, in order to suppress the change of a voltage of a pixel due to the leak current, an auxiliary capacitor 68 is provided in parallel with a capacitor of the pixel (FIG. 4).
[0011] Various methods of forming an auxiliary capacitor have been proposed, and the most typical structure of the auxiliary capacitor uses the overlap of an active layer (semiconductor layer) of a thin-film transistor and a gate wiring line.
[0012] [0012]FIGS. 3A to 3 E show the state of a cross section of an active matrix type circuit using top-gate type thin-film transistors, while explaining the manufacturing steps. An intrinsic active layer 42 is formed on a substrate 41 , and is selectively doped with N-type or P-type impurities to form a conductive region 44 . Further, a gate insulating film 43 is formed so as to cover the active layer, and gate wiring lines 45 and 46 are formed (FIG. 3A).
[0013] In general, the gate wiring lines 45 and 46 use wiring lines in rows different from each other. In the pixel shown in the drawing, the gate wiring line 45 functions as a gate electrode of the thin-film transistor, and the gate wiring 46 functions as an electrode of an auxiliary capacitor 49 . The reason why the wiring lines in the different rows are used is that if the gate wiring lines 45 and 46 are those in the same row, parasitic capacitance between a drain and the gate electrode of the thin-film transistor becomes extremely large, so that it constitutes an obstacle to a switching function. In the drawing, the gate wiring 46 is for constituting the auxiliary capacitor, and another wiring line for only increasing an aperture ratio is not generally formed.
[0014] Next, impurities having the same conductivity as the conductive region 44 are implanted while using the gate electrode as a mask so that a source 47 and a drain 48 are formed in a self-alignment manner. In this way, the auxiliary capacitor 49 is formed between the gate wiring line 46 , and the conductive region 44 and the drain 48 (FIG. 3B).
[0015] Thereafter, a first interlayer insulator including a silicon nitride layer 50 as a passivation film and a layer 51 of a material suitable for flattening such as polyimide, is formed and is etched so that a contact hole reaching to the source 47 is formed. Then, a data wiring line 52 is provided (FIG. 3C).
[0016] Since the conductivity of the thin-film transistor is varied by irradiation of light, in order to prevent the variation, a coating film (black matrix) 54 having light shielding properties is overlapped on the thin-film transistor. Further, in order to prevent mixing of colors and degrees of brightness between pixels and to prevent poor display due to the disturbance of an electric field at boundary portions of the pixels, the above light shielding coating film is also formed between pixels. Thus, the light shielding coating film has a matrix shape so that it is called a black matrix (BM). The BM 54 is formed on a second interlayer insulator 53 (FIG. 3D).
[0017] Thereafter, a third interlayer insulator 55 is formed, and is etched to form a contact hole reaching to the drain 48 (or conductive region 44 ). Further, a pixel electrode 56 is formed of a transparent conductive coating film. If the BM is formed of an insulating material, the third interlayer insulator 55 is not necessary (FIG. 3E).
[0018] Among the above steps, main steps are enumerated as follows.
[0019] A forming step of the active layer 42
[0020] B selective doping step for forming the conductive region 44
[0021] C forming step of the gate insulating film 43
[0022] D forming step of the gate wiring lines 45 and 46
[0023] E self-alignment doping step for forming the source 47 and the drain 48
[0024] F forming step of the first interlayer insulators 50 and 51
[0025] G forming step of the contact hole
[0026] H forming step of the data wiring line 52
[0027] I forming step of the second interlayer insulator 53
[0028] J forming step of the black matrix 54
[0029] K forming step of the third interlayer insulator 55
[0030] L forming step of the contact hole
[0031] M forming step of the pixel electrode 56
[0032] Among the above steps, eight steps A, B, D, G, H, J, L and M are accompanied by a photolithography step.
[0033] [0033]FIGS. 10A to 10 D show the state of a cross section of an active matrix circuit using bottom-gate type thin-film transistors while explaining the manufacturing steps. A gate wiring line 172 and a capacitor wiring line 173 are formed on a substrate 171 . The capacitor wiring line 173 may also serves as a gate wiring line, and in this case, an opening region can be made large as compared with the case where the capacitor wiring line is especially provided.
[0034] In the case where the capacitor wiring line 173 is used as the gate wiring line, the wiring line of a row different from the gate wiring line 172 is used. If the gate wiring line 172 and the wiring line 173 are in the same row, parasitic capacitance between the drain and the gate electrode of the thin-film transistor becomes extremely large, so that switching is hindered.
[0035] Incidentally, in the case where the capacitor wiring line 173 serves also as the gate wiring line, there is also such a defect that the parasitic capacitance of the wiring line becomes large so that the operation speed slows down and the signal shape becomes dull.
[0036] Next, a gate insulating film 174 covering these wiring lines, and an intrinsic semiconductor layer 175 are formed. Further, conductive regions (source, drain) 176 and 177 , which are doped with N-type or P-type impurities and are connected to the semiconductor layer 175 , are formed. Further, a data wiring line 178 is formed (FIG. 10A).
[0037] In this way, an auxiliary capacitor 179 including the gate insulating film 174 as a dielectric is obtained between the capacitor wiring line 173 and the conductive region 177 .
[0038] Thereafter, a first interlayer insulator including a silicon nitride film 180 as a passivation film and a layer 181 made of a resin material suitable for flattening, such as polyimide, is formed (FIG. 10B).
[0039] Since the conductivity of the thin-film transistor is changed by irradiation of light, in order to prevent the variation, a coating film (black matrix) 182 having light shielding properties is overlapped on the thin-film transistor. Further, in order to prevent the mixture of colors and degrees of brightness between pixels and to prevent poor display due to the disturbance of an electric field at boundary portions of the pixels, the above light shielding coating film is also formed between the pixels. Thus, the light shielding coating film has a matrix shape so that it is called a black matrix (BM). If the BM 182 is formed on the substrate on which the active matrix circuit is provided, it has an effect in integration of pixels. In this case, the BM 182 is formed on the polyimide layer 181 of the first interlayer insulator (FIG. 10C).
[0040] Thereafter, a second interlayer insulator 183 is formed. The second and the first interlayer insulators are etched to form a contact hole reaching to the conductive region 177 . Further, pixel electrodes 184 and 185 (pixel electrodes of other pixels) are formed of a transparent conductive coating film. In general, the BM and the pixel electrodes are formed so as not to form a portion where they are not overlapped with each other. If the BM 182 is formed of an insulating material, the second interlayer insulator 183 is not necessary (FIG. 10D).
[0041] The active matrix circuit of the above structure has a feature that since the gate insulating film having a high withstand voltage can be used as an insulator (dielectric) of the auxiliary capacitor, large capacitance can be obtained.
[0042] However, in some cases, the capacitance is insufficient. In order to increase the auxiliary capacitance, the area occupied by the capacitor wiring line must be increased. That is, according to a conventional method, the auxiliary capacitor has a main structure of two-dimensional extension. However, since the portion where the capacitor wiring line is disposed, does not transmit light, an opening rate is lowered.
[0043] Further, the conventional method has a defect that since the gate wiring also serves as the electrode of the auxiliary capacitor, the parasitic capacitance of the wiring line becomes large, so that the operation speed slows down and the signal shape becomes dull. With respect to this defect, there is a method in which the gate wiring line and the wiring line of the auxiliary capacitor are separately provided. However, as described above, the area occupied by the wiring lines is increased by that, so that the opening rate is lowered.
[0044] The present invention intends to solve these problems and to increase auxiliary capacitance by constituting an auxiliary capacitor in three-dimension without lowering an aperture ratio.
[0045] Further, the active matrix circuit using top-gate type thin-film transistors has such a defect that two doping steps are necessary, and a photolithography step is necessary to define a doping region for the purpose of forming the conductive region 44 .
[0046] With respect to this defect, if doping of the source and drain is also carried out in the stage of the above step B, the number of doping steps can be made one. However, in that case, a self-alignment type transistor can not be made, parasitic capacitance is large, and there is a fear that the parasitic capacitance would vary for each transistor. Further, also in this case, the photolithography step at doping is necessary.
[0047] The steps of this improved conventional method are as follows.
[0048] A forming step of the active layer 42
[0049] B′ selective doping step for forming the conductive region 44 , source 47 , and drain 48
[0050] C forming step of the gate insulating film 43
[0051] D forming step of the gate wiring lines 45 and 46
[0052] (there is no step corresponding to step E)
[0053] F forming step of the first interlayer insulators 50 and 51
[0054] G forming step of the contact hole
[0055] H forming step of the data wiring line 52
[0056] I forming step of the second interlayer insulator 53
[0057] J forming step of the black matrix 54
[0058] K forming step of the third interlayer insulator 55
[0059] L forming step of the contact hole
[0060] M forming step of the pixel electrode 56
[0061] Among the above steps, eight steps A, B, D, G, H, J, L and M are accompanied by the photolithography step.
SUMMARY OF THE INVENTION
[0062] The present invention has been made to improve the problems of the above steps.
[0063] According to the present invention, an active matrix circuit using top-gate type thin-film transistors is characterized in that a capacitor as an auxiliary capacitor is formed between a black matrix and an N-type or P-type active layer, and a silicon nitride layer (silicon nitride layer 50 in FIG. 3C) used as a passivation film of a first interlayer insulator is used as a dielectric of the auxiliary capacitor.
[0064] Further, according to the present invention, an active matrix circuit using bottom-gate type thin-film transistors is characterized in that a capacitor as an auxiliary capacitor is formed between a black matrix and an N-type or P-type conductive region (semiconductor layer) or a metal wiring line connected to the conductive region, and a silicon nitride layer (silicon nitride layer 180 in FIG. 10B) used as a passivation film of a first interlayer insulator is used as a dielectric of the auxiliary capacitor.
[0065] An active matrix type display circuit of the present invention comprises:
[0066] (1) top-gate type thin-film transistors,
[0067] (2) an N-type or P-type active layer,
[0068] (3) a conductive film functioning as a black matrix and kept at a constant potential,
[0069] (4) a gate wiring line and a data wiring line,
[0070] (5) a first interlayer insulator including a silicon nitride layer and a polyimide layer (the silicon nitride layer is located under the polyimide layer), and being positioned between the gate wiring line and the data wiring line, and
[0071] (6) a second interlayer insulator positioned between the data wiring line and the conductive coating film.
[0072] A first aspect of the invention is characterized in that in the above structure, an auxiliary capacitor, which includes the active layer and the conductive coating film as both electrodes, and at least the silicon nitride layer of the first interlayer insulator as a dielectric, is formed at a portion where the polyimide layer of the first interlayer insulator and the second interlayer insulator are etched.
[0073] A second aspect of the invention is characterized in that in the above structure, the silicon nitride layer is located under the polyimide layer in the first interlayer insulator, and the conductive coating film has a portion which is in contact with the silicon nitride layer of the first interlayer insulator at a portion where the conductive coating film overlaps with the active layer.
[0074] In the first or second aspect of the invention, if the active layer functioning as an electrode of the auxiliary capacitor is continuous with the source or drain of the thin-film transistor, the circuit structure is simple and an occupied area can be decreased.
[0075] The dielectric of the auxiliary capacitor may be a multilayer structure of the gate insulating film and the silicon nitride layer, or only the silicon nitride layer. In the former case, by utilizing the property of a withstand voltage of the gate insulating film, a possibility of short-circuiting is lowered. In the latter case, the dielectric becomes thin, and by using the silicon nitride having large dielectric constant, larger capacitance can be obtained.
[0076] In the first or second aspect of the invention, the thickness of the silicon nitride layer is not larger than 1000 Å, preferably not larger than 500 Å.
[0077] The main steps for obtaining the present invention of the above structure are as follows.
[0078] a forming step of an active layer
[0079] (there is no step corresponding to step B)
[0080] c forming step of a gate insulating film
[0081] d forming step of a gate wiring line
[0082] e self-alignment doping step for forming a source and a drain (conductive region)
[0083] f forming step of a first interlayer insulator (containing a silicon nitride layer)
[0084] g forming step of a contact hole
[0085] h forming step of a data wiring line
[0086] i forming step of a second interlayer insulator
[0087] x etching step of a hole for an auxiliary capacitor
[0088] j forming step of a black matrix
[0089] k forming step of a third interlayer insulator
[0090] l forming step of a contact hole
[0091] m forming step of a pixel electrode
[0092] Among the above steps, eight steps a, d, g, h, x, j, l and m are accompanied by a photolithography step.
[0093] The number of total steps of the present invention is thirteen, while the number of those of the conventional method is thirteen and the number of those of the conventional improved method is twelve. Accordingly, although it appears that the method of the present invention is inferior to the conventional improved method, the invention is superior in that the thin-film transistor is formed in a self-alignment manner, so that although the number of steps is increased by one, the present invention is still superior to the conventional method and the conventional improved method.
[0094] With respect to the number of photolithography steps, the number is identical among the conventional method, the convention improved method, and the present invention. Since the thin-film transistor is a self-alignment type, the present invention is equivalent to the conventional method, and it is concluded that the present invention is superior to the conventional method in that the number of doping steps is one.
[0095] The invention is superior in mass production since the number of doping can be made one, as described above. In addition, in the present invention, since the gate wiring line is not an electrode of the auxiliary capacitor, there does not occur such a problem that a gate signal becomes dull. However, this does not deny the combination of the present invention with the prior art. It is useful to obtain larger capacitance by the combination. Further, in addition to the above step, further steps may be added to make the circuit of a higher order, which is also included in the scope of the present invention. For example, it does not matter even if the number of steps are increased to manufacture an advanced thin-film transistor. The same may be said of the wiring structure.
[0096] Another active matrix type display circuit of the present invention comprises:
[0097] (1) bottom-gate type thin-film transistors,
[0098] (2) a gate wiring line and a data wiring line,
[0099] (3) a conductive coating film functioning as a black matrix and kept at a constant potential,
[0100] (4) an N-type or P-type semiconductor layer (or a metal wiring line connected to the semiconductor layer and located in the same layer as the data wiring line), and
[0101] (5) an interlayer insulator including a silicon nitride layer and a polyimide layer (the silicon nitride layer is located under the polyimide layer), and being positioned between the conductive coating film and the data wiring line.
[0102] A third aspect of the present invention is characterized in that in the above structure, an auxiliary capacitor, which includes the semiconductor layer (or a metal wiring line) and the conductive coating film as both electrodes, and at least the silicon nitride layer of the interlayer insulator as a dielectric, is formed at a portion where the polyimide layer of the interlayer insulator was etched.
[0103] A fourth aspect of the present invention is characterized in that in the above structure, the silicon nitride layer is under the polyimide layer in the interlayer insulator, and the conductive coating film has a portion which is in contact with the silicon nitride layer of the interlayer insulator at a portion where the conductive coating film overlaps with the semiconductor layer (or metal wiring line).
[0104] In the third or fourth aspect of the invention, if the semiconductor layer functioning as an electrode of the auxiliary capacitor is continuous with the source or drain of the thin-film transistor, the circuit structure is simple and the occupied area can be decreased.
[0105] The dielectric of the auxiliary capacitor may be only the silicon nitride layer or a multilayer structure of the silicon nitride layer and other coating film (for example, silicon oxide). In the former case, the dielectric becomes thin, and by using the silicon nitride having large dielectric constant, larger capacitance can be obtained. In the third or fourth aspect of the invention, the thickness of silicon nitride layer is not larger than 1000 Å, preferably not larger than 500 Å.
[0106] In the present invention, it is possible to overlap the portion where the auxiliary capacitor is formed by the above structure with the portion where the auxiliary capacitor is formed by the method shown in FIGS. 10A to 10 D. In that case, the auxiliary capacitor of the present invention overlaps with the capacitor wiring line. By this, since the auxiliary capacitor is formed into a multilayer configuration, it is possible to increase the capacitance without lowering an open rate.
[0107] When the present invention is practiced, a required step is only an etching step of the polyimide layer, and other steps of film forming, etching and the like are unnecessary. Thus, there is no difficulty in practicing the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0108] In the accompanying drawings:
[0109] [0109]FIGS. 1A to 1 E are sectional views showing manufacturing steps of an active matrix circuit of a first embodiment of the present invention;
[0110] [0110]FIGS. 2A to 2 E are sectional views showing manufacturing steps of an active matrix circuit of a second embodiment of the present invention;
[0111] [0111]FIGS. 3A to 3 E are sectional views showing manufacturing steps of an active matrix circuit using conventional top-gate type thin-film transistors;
[0112] [0112]FIG. 4 is a circuit diagram of a general active matrix circuit;
[0113] [0113]FIGS. 5A and 5B are top views showing manufacturing steps of the active matrix circuit of the first embodiment of the present invention;
[0114] [0114]FIGS. 6A to 6 D are sectional views showing manufacturing steps of an active matrix circuit of a third embodiment of the present invention;
[0115] [0115]FIGS. 7A to 7 E are sectional views showing manufacturing steps of an active matrix circuit of a fourth embodiment of the present invention;
[0116] [0116]FIGS. 8A and 8B are top views showing manufacturing steps of the active matrix circuit of the third embodiment of the present invention;
[0117] [0117]FIGS. 9A to 9 E are sectional views showing manufacturing steps of an active matrix circuit of a fifth embodiment of the present invention; and
[0118] [0118]FIGS. 10A to 10 D are sectional views showing manufacturing steps of an active matrix circuit using conventional bottom-gate type thin-film transistors.
DETAILED DESCRIPTION OF THE INVENTION
[0119] [Embodiment 1]
[0120] Manufacturing steps of this embodiment will be shown in FIGS. 1A to 1 E. First, a silicon oxide film with a thickness of 3000 Å as an under layer film is formed on a glass substrate 1 by a sputtering method or a plasma CVD method, and then an amorphous silicon film with a thickness of 500 Å is formed by the plasma CVD method or a reduced pressure thermal CVD method. A crystalline silicon film is obtained by heating or laser light irradiation to the amorphous silicon film. The crystalline silicon film is etched so that an active layer 2 of a thin-film transistor is obtained.
[0121] Next, a silicon oxide film 3 with a thickness of 1000 Å as a gate insulating film is formed by the plasma CVD method, the low pressure thermal CVD method, or the sputtering method. A polycrystalline silicon film containing phosphorus and having a thickness of 5000 Å is formed by the reduced pressure CVD method, and is etched to obtain a gate wiring line 4 . (FIG. 1A)
[0122] Next, by implantation of impurity ions of phosphorus giving an N-type with a dose of 5×10 14 to 5×10 15 atoms/cm 3 , a source 5 and a drain 6 are formed. Any of them become an N-type. After implantation of impurity ions, the region where the impurity ions were implanted is activated by carrying out heat treatment, laser light irradiation, or intense light irradiation. (FIG. 1B)
[0123] Next, a silicon nitride film 7 is formed by the plasma CVD method using silane and ammonia, silane and N 2 O, or silane, ammonia and N 2 O. The thickness of the silicon nitride film 7 is 250 to 1000 Å, and 500 Å in this embodiment. The film forming method of the silicon nitride may be a method using dichlorsilane and ammonia. Also, the low pressure thermal CVD method or photo CVD method may be used.
[0124] After formation of the silicon nitride film, by carrying out a heat treatment at a temperature of 350° C. for two hours, annealing is conducted to the surfaces of the silicon oxide film 3 , the source 5 and drain 6 damaged by the previous impurity ion implantation. In this step, hydrogen is diffused from the silicon nitride film 7 , so that defects in the silicon oxide film 3 and the surfaces of the source 5 and drain 6 are removed. Further, hydrogen is diffused into a channel forming region under the gate wiring 4 so that defects in the region are removed.
[0125] Subsequently, by a spin coating method, a polyimide layer 8 with a thickness of at least 8000 Å, preferable 1.5 μm is formed. The surface of the polyimide layer is made flat. Thus, an interlayer insulator including the silicon nitride layer 7 and the polyimide layer 8 are formed.
[0126] Thereafter, the polyimide layer 8 , the silicon nitride layer 7 , and the silicon oxide film 3 are etched to form a contact hole reaching to the source 5 . Further, an aluminum film with a thickness of 6000 Å is formed by the sputtering method, and is etched to form a data wiring line 9 . The data wiring line 9 comes in contact with the source 5 . (FIG. 1C)
[0127] [0127]FIG. 5A shows the state of the circuit obtained in these steps seen from the above. Reference numerals correspond to those in FIGS. 1A and 1C. (FIG. 5A)
[0128] Next, a polyimide layer 10 is formed as a second interlayer insulator with a thickness of 8000 Å. Then, the polyimide layers 8 and 10 are etched to form a hole for an auxiliary capacitor. Further, a titanium film with a thickness of 1000 Å is formed by the sputtering method. Of course, a metal film such as a chromium film or an aluminum film may be used. The titanium film is etched to form a black matrix 11 . The black matrix is formed so as to cover the previously formed hole for the auxiliary capacitor. (FIG. 1D)
[0129] [0129]FIG. 5B shows the hole 14 for the auxiliary capacitor and the black matrix 11 obtained in these steps seen from the above. Reference numerals correspond to those in FIGS. 1D and 1E. The auxiliary capacitor is formed at a portion where the black matrix 11 overlaps with the hole 14 for the auxiliary capacitor. (FIG. 5B)
[0130] Further, as a third interlayer insulator, a polyimide film 12 with a thickness of 5000 Å is formed, and the polyimide films 8 , 10 and 12 , the silicon nitride layer 7 , and the silicon oxide film 3 are etched so that a contact hole reaching to the drain 6 is formed. Further, an ITO (Indium Tin Oxide) film with a thickness of 1000 Å is formed by the sputtering method, and is etched to form a pixel electrode 13 (FIG. 1E).
[0131] In this way, an active matrix circuit is completed. When the insulating layer is formed by the polyimide film as in this embodiment, flattening is easy and remarkable effects are obtained. In this embodiment, the auxiliary capacitor is obtained at the portion 14 where the black matrix 11 overlaps with the drain 6 , and the dielectric is a multilayer film consisting of the silicon oxide film 3 used as the gate insulating film and the silicon nitride layer 7 . Of course, since the silicon oxide film 3 is considerably damaged by the subsequent doping step, although it does not have such resistance as to be used as the gate insulating film, the insulation property thereof is sufficient.
[0132] [Embodiment 2]
[0133] Manufacturing steps of this embodiment will be shown in FIGS. 2A to 2 E. First, an active layer 22 of a crystalline silicon film with a thickness of 1000 Å is formed on a quartz substrate 21 coated with an under layer film. The active layer is thermally oxidized so that a silicon oxide film 23 with a thickness of 1000 Å is obtained on the surface thereof. The silicon oxide film 23 functions as a gate insulating film. Further, a polycrystalline silicon film containing phosphorus with a thickness of 5000 Å is formed by the low pressure CVD method, and is etched to obtain a gate wiring line 24 .(FIG. 2A)
[0134] Next, impurity ions of phosphorus giving an N-type with a dose of 5×10 12 to 5×10 13 atoms/cm 3 is implanted, so that a low concentration impurity region 28 is obtained. Further, by using a well known side wall forming technique employing an anisotropic etching technique, a side wall 25 of an insulator is obtained at a side surface of the gate wiring line 24 . At that time, the silicon oxide film 23 is etched except the portion under the gate wiring 24 and the side wall 25 so that only the gate insulating film 26 remains.
[0135] In this state, ions of phosphorus with a dose of 5×10 14 to 5×10 15 atoms/cm 3 are implanted, so that a source 29 and a drain 27 are formed. After implantation of the impurity ions, a heat treatment is carried out so that the region where the impurity ions were injected is activated. The details of the above doping step are disclosed in, for example, Japanese Patent Unexamined Publication No. 8-18055. (FIG. 2B)
[0136] Next, a silicon nitride layer 30 and a polyimide layer 31 are formed under the same conditions as the first embodiment. Unlike the first embodiment, in this embodiment, the silicon nitride layer 30 is brought into direct contact with the source 29 and the drain 27 . Next, the silicon nitride layer 30 and the polyimide layer 31 are etched to form a contact hole reaching to the source 29 . Further, an aluminum film with a thickness of 6000 Å is formed by the sputtering method, and is etched to form a data wiring line 32 . The data wiring line 32 is brought into contact with the source 29 . The state of the circuit obtained in these steps seen from the above is equivalent to that shown in FIG. 5A. (FIG. 2C)
[0137] Next, a polyimide layer 33 is formed as a second interlayer insulator with a thickness of 8000 Å. Then, the polyimide layers 31 and 33 are etched to form a hole for an auxiliary capacitor. Further, a titanium film with a thickness of 1000 Å is formed by the sputtering method, and is etched to form a black matrix 34 . The state of the circuit obtained in these steps seen from the above is equivalent to that shown in FIG. 5B. (FIG. 2D)
[0138] Further, a polyimide film 35 with a thickness of 5000 Å is formed as a third interlayer insulator, and the polyimide films 31 , 33 and 35 and the silicon nitride layer 30 are etched to form a contact hole reaching to the drain 27 . Further, an ITO (Indium Tin Oxide) film with a thickness of 1000 Å is formed by the sputtering method, and is etched to form a pixel electrode 36 . (FIG. 2E)
[0139] In this way, an active matrix circuit is completed. In this embodiment, the auxiliary capacitor is obtained at a portion 37 where the black matrix overlaps with the drain 27 , and a dielectric of the auxiliary capacitor is the silicon nitride layer 30 . Since the silicon nitride has high dielectric constant, large capacitance is obtained with a small area.
[0140] [Embodiment 3]
[0141] Manufacturing steps of this embodiment will be shown in FIGS. 6A to 6 D. First, a gate wiring line 102 and a capacitor wiring line 103 are formed of a tantalum film with a thickness of 4000 Å on a glass substrate 101 having a silicon oxide film with a thickness of 3000 Å formed by the sputtering method or plasma CVD method as an under layer film. An oxide coating film may be formed on the surfaces of the wiring lines by anodic oxidation. By this, the insulation property can be increased.
[0142] Next, a silicon oxide film 104 as a gate insulating film with a thickness of 1000 Å is formed by the plasma CVD method, the low pressure thermal CVD method, or the sputtering method. The gate insulating film may be a multilayer film of a silicon nitride film and a silicon oxide film.
[0143] Further, an amorphous silicon film with a thickness of 500 Å is formed by the plasma CVD method or the low pressure thermal CVD method. This film may be changed into a crystalline film by heating or laser light irradiation. The thus obtained amorphous silicon film (or crystalline silicon film) is etched to obtain a semiconductor layer (active layer) 105 of a thin-film transistor.
[0144] Next, a polycrystalline silicon film containing phosphorus with a thickness of 5000 Å is formed by the low pressure CVD method, and is etched to obtain a source 106 and a drain 107 . Further, by using an aluminum film with a thickness of 6000 Å, a data wiring line 108 is obtained. In the above, a first auxiliary capacitor 109 including a dielectric of the gate insulating film 104 is formed between the capacitor wiring line 103 and the drain 107 . (FIG. 6A)
[0145] [0145]FIG. 8A shows the state of the circuit obtained in these steps seen from the above. Reference numerals correspond to those in FIG. 6A.
[0146] Next, a silicon nitride film 110 is formed by the plasma CVD method using silane and ammonia, silane and N 2 O, or silane, ammonia and N 2 O. This silicon nitride film 110 has a thickness of 250 to 1000 Å, and 500 Å in this embodiment. The silicon nitride film may be formed by a method using dichlorsilane and ammonia. Also, the reduced pressure thermal CVD method or photo CVD method may be used.
[0147] Subsequently, by a spin coating method, a polyimide layer 111 with a thickness of at least 8000 Å, preferably 1.5 μm is formed. The surface of the polyimide layer is made flat. In this way, a first interlayer insulator consisting of the silicon nitride layer 110 and the polyimide layer 111 is formed. Then, the polyimide layer 111 is etched to form a hole 112 for an auxiliary capacitor. (FIG. 6B)
[0148] Further, a titanium film with a thickness of 1000 Å is formed by the sputtering method. Of course, a metal film such as a chromium film or an aluminum film may be used.
[0149] Then, the titanium film is etched to form a black matrix 113 . The black matrix is formed so as to cover the previously formed hole 112 for the auxiliary capacitor. In this way, at the hole 112 for the auxiliary capacitor, a second auxiliary capacitor 114 with a dielectric of the silicon nitride layer 110 is formed between the black matrix 113 and the drain 107 (FIG. 6C).
[0150] [0150]FIG. 8B shows the state of the hole 112 for the auxiliary capacitor and the black matrix 113 obtained in these steps seen from the above. Reference numerals correspond to those in FIGS. 6B and 6C. A second auxiliary capacitor is formed at a portion where the black matrix 113 overlaps with the hole 112 for the auxiliary capacitor. (FIG. 8B)
[0151] Further, as a second interlayer insulator, a polyimide film 115 with a thickness of 5000 Å is formed, and the polyimide films 111 and 115 and the silicon nitride layer 110 are etched to form a contact hole reaching to the drain 107 . Further, an ITO (Indium Tin Oxide) film with a thickness of 1000 Å is formed by the sputtering method, and is etched to form pixel electrodes 116 and 117 . (FIG. 6D)
[0152] In this way, an active matrix circuit is completed. When the insulating layer is formed by the polyimide film as in this embodiment, flattening is easy and remarkable effects can be obtained.
[0153] [Embodiment 4]
[0154] Manufacturing steps of this embodiment will be shown in FIGS. 7A to 7 E. First, a gate wiring line 122 and a capacitor wiring line 123 are formed of an aluminum film with a thickness of 3000 Å on a glass substrate 121 coated with an underlying film. An oxide coating film may be formed on the surface of these wiring lines by anodic oxidation. By this, the insulation property can be increased. Next, a silicon oxide film 124 as a gate insulating film with a thickness of 1000 Å is formed by the plasma CVD method. The gate insulating film may be a multilayer film of a silicon nitride film and a silicon oxide film.
[0155] Further, an amorphous silicon film with a thickness of 500 Å is formed by the plasma CVD method or the low pressure thermal CVD method. The amorphous silicon film may be changed into a crystalline silicon film by heating or laser light irradiation. The thus obtained amorphous silicon film (or crystalline silicon film) is etched to obtain a semiconductor layer (active layer) 125 of a thin-film transistor.
[0156] Next, impurity ions of phosphorus giving N-type with a dose of 5×10 14 to 5×10 15 atoms/cm 3 is selectively implanted into the semiconductor layer 125 , so that a source 126 and a drain 127 are obtained. After implantation of the impurity ions, the region where the impurity ions were implanted may be activated by a heat treatment, laser light irradiation or the like. (FIG. 7A)
[0157] Next, a data wiring line 128 and a wiring line (drain wiring line) 129 connected to the drain are obtained by using an aluminum film with a thickness of 6000 Å. In the above, a first auxiliary capacitor 130 including a dielectric of the gate insulating film 124 is formed between the capacitor wiring line 123 and the drain wiring line 129 . (FIG. 7B)
[0158] Next, a silicon nitride layer 131 and a polyimide layer 132 are formed under the same conditions as in the third embodiment. Next, the polyimide layer 132 is etched to form a hole 133 for an auxiliary capacitor. (FIG. 7C)
[0159] Further, a titanium film with a thickness of 1000 Å is formed by the sputtering method. Of course, a metal film such as a chromium film or an aluminum film may be used. Then, the titanium film is etched to form a black matrix 134 . In this way, at the hole 133 for the auxiliary capacitor, a second auxiliary capacitor 135 including a dielectric of the silicon nitride layer 131 is formed between the black matrix 134 and the drain wiring line 129 . (FIG. 7D)
[0160] Further, a polyimide film 136 with a thickness of 5000 Å is formed as a second interlayer insulator, and the polyimide films 132 and 136 , and the silicon nitride layer 131 are etched to form a contact hole reaching to the drain wiring line 129 . Further, an ITO (Indium Tin Oxide) film with a thickness of 1000 Å is formed, and is etched to form pixel electrodes 137 and 138 .
[0161] (FIG. 7E)
[0162] [Embodiment 5]
[0163] Manufacturing steps of this embodiment will be shown in FIGS. 9A to 9 E. First, a gate wiring line 152 and a capacitor wiring line 153 are formed of a tantalum film with a thickness of 4000 Å on a glass substrate 151 coated with an underlying film. An oxide coating film may be formed on the surfaces of these wiring lines by anodic oxidation. By this, the insulation property can be increased. Next, a silicon oxide film 154 with a thickness of 1000 Å is formed as a gate insulating film by the plasma CVD method. The gate insulating film may be a multilayer film of a silicon nitride film and a silicon oxide film.
[0164] Further, an amorphous silicon film with a thickness of 500 Å is formed by the plasma CVD method. The thus obtained amorphous silicon film is etched to obtain a semiconductor layer (active layer) 155 of a thin-film transistor.
[0165] Next, impurity ions of phosphorus giving an N-type with a dose of 5×10 14 to 5×10 15 atoms/cm 3 are selectively implanted into the semiconductor layer 155 , so that a source 156 and a drain 157 are obtained. After implantation of the impurity ions, the region where the impurity ions were implanted may be activated by a heat treatment, laser irradiation or the like.
[0166] (FIG. 9A)
[0167] Next, a data wiring line 158 is obtained by using an aluminum film with a thickness of 6000 Å. In the above, the semiconductor layer 155 is formed so as to overlap with the capacitor wiring line 153 . Accordingly, a first auxiliary capacitor 159 with a dielectric of the gate insulating film 154 is formed between the capacitor wiring line 153 and the drain 157 . (FIG. 9B)
[0168] Next, a silicon nitride layer 160 and a polyimide layer 161 are formed under the same conditions as in the third embodiment. Next, the polyimide layer 161 is etched to form a hole 162 for an auxiliary capacitor. (FIG. 9C)
[0169] Further, a titanium film with a thickness of 1000 Å is formed by the sputtering method, and the titanium film is etched to form a black matrix 163 . In this way, at the hole 162 for the auxiliary capacitor, a second auxiliary capacitor including a dielectric of the silicon nitride layer 160 is formed between the black matrix 163 and the drain 157 . (FIG. 9D)
[0170] Further, a polyimide film 165 with a thickness of 5000 Å is formed as a second interlayer insulator, and the polyimide films 161 and 165 and the silicon nitride layer 160 are etched so that a contact hole reaching to the drain 157 is formed. Further, an ITO (Indium Tin Oxide) film with a thickness of 1000 Å is formed by the sputtering method, and is etched to form pixel electrodes 166 and 167 (FIG. 9E).
[0171] As is apparent from the foregoing description, it has become clear that in an active matrix circuit using top-gate type thin-film transistors, when an auxiliary capacitor is formed of electrodes of an N-type or P-type active layer and a conductive coating film used as a black matrix, and a dielectric of a silicon nitride layer formed as a passivation film, conventional problems can be solved.
[0172] Also, it has become clear that in an active matrix circuit using bottom-gate type thin-film transistors, when an auxiliary capacitor is formed of electrodes of an N-type or P-type semiconductor layer or a wiring line connected thereto and a conductive coating film used as a black matrix, and a dielectric of a silicon nitride layer formed as a passivation film, conventional problems can be solved.
[0173] As described above, the present invention is useful in industry. | An active matrix circuit using top-gate type thin-film transistors is characterized in that an auxiliary capacitor is formed between a black matrix and an N-type or P-type active layer, and uses, as a dielectric, a silicon nitride layer used as a passivation film of an interlayer insulator. Also, an active matrix circuit using bottom-gate type thin-film transistors is characterized in that two auxiliary capacitors. One of the auxiliary capacitors is formed between a capacitor wiring line formed on a substrate and an N-type or P-type conductive region or a metal wiring line connected to the conductive region, and uses a gate insulating film as a dielectric. The other one of the auxiliary capacitors is formed between a black matrix and said N-type or P-type conductive region or said metal wiring line connected to the conductive region, and uses a silicon nitride layer used as a passivation film as a dielectric. Said two auxiliary capacitors are located in three-dimension for preventing aperture ratio from lowering. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of an earlier filing date from U.S. Provisional Application Ser. No. 61/739,606 filed Dec. 19, 2012, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
Screen assemblies are ubiquitous in the downhole drilling and completions industry for enabling solids or particulate to be filtered from a flow of fluid, e.g., hydrocarbons, while enabling production of the fluid. Production and stimulation rates through the screen assemblies can be generally increased by increasing the size of the screen assembly. Additionally, it is well established that certain radial clearances between the outer dimension of the screen assembly and the inner dimension of the casing (or other tubular string) in which the screen assembly is positioned must be maintained in order to support stimulation and/or production at appropriate rates. For example, if the radial gap is undesirably small, there is a severe risk of premature screen outs and/or the sand or particulate in a frac or gravel pack bridging off before filling the annulus about a screen assembly. For the above reasons, it is established practice in the industry to use screen assemblies having dimensions that are significantly smaller than the drift diameter of the casing in order to maintain the aforementioned radial clearance in the range of about at least 0.5 inches.
Although maintaining the radial clearance is necessary to support industry accepted production and stimulation rates, it also puts a limit on the maximum possible size of the screen assemblies, which negatively impacts these same rates. The simultaneous use of a larger screen assembly and maintenance of the radial clearance is only possible in these prior systems by using larger casing, but this requires greater material costs and potentially a larger borehole. In view hereof, it is clear that the industry would well receive a system that enables larger screen assemblies to be used within a given size of casing without negatively affecting production and stimulation rates, e.g., by reducing the size of the radial clearance between the screen assembly and the casing to an unacceptable level.
SUMMARY
A method of completing a borehole, including selectively expanding a tubular string having a substantially continuous first dimension to form at least one expanded portion of the tubular string having a second dimension greater than the first dimension and at least one unexpanded portion of the tubular string having the first dimension; and positioning at least one screen assembly radially proximate to the at least one expanded portion for forming an enlarged radial gap between the at least one screen assembly and the expanded portion of the tubular string.
A completion system, including a tubular string having an internal drift dimension and including at least one expanded portion having an expanded internal dimension larger than the internal drift dimension, the tubular string having at least one opening therein formed at the at least one expanded portion; and at least one screen assembly having an outer dimension approximating the internal drift dimension, the at least one screen assembly positioned radially aligned with the at least one expanded portion, wherein the outer dimension and the expanded dimension form a radial clearance therebetween being at least about 0.5 inches.
A method of completing a borehole, including selectively expanding a tubular string having a substantially continuous first dimension to form at least one expanded portion of the tubular string having a second dimension greater than the first dimension and at least one unexpanded portion of the tubular string having the first dimension; and positioning at least one screen assembly radially proximate to the at least one expanded portion for forming an enlarged radial gap between the at least one screen assembly and the expanded portion of the tubular string.
BRIEF DESCRIPTION OF THE DRAWINGS
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
FIG. 1 is a cross-sectional view of a completion system disclosed herein having a liner hung from an upper completion string;
FIG. 2 is a cross-sectional view of the completion system of FIG. 1 being selectively radially expanded to form at least one expanded portion and at least one unexpanded portion;
FIG. 3 is a cross-sectional view of the completion system of FIG. 2 having an annulus between a casing and a borehole being cemented;
FIG. 4 is a cross-sectional view of the completion system of FIG. 3
FIG. 5 is a cross-sectional view of the completion system of FIG. 4 having a screen assembly positioned radially proximate each of the expanded portions for forming an enlarged radial gap between the screen assembly and the corresponding expanded portion; and
FIG. 6 is a cross-sectional view of an alternate embodiment disclosed herein wherein an expanded portion corresponds to multiple screen assemblies.
DETAILED DESCRIPTION
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Methods for deploying a downhole production system can be best appreciated in view of FIGS. 1-5 , in which a completion system 10 is progressively completed. In FIG. 1 , a casing 12 or other outer tubular of the completion system 10 comprises a production liner 14 or other tubular string that is hung, anchored, or suspended from an upper casing string 16 , which may extend to surface or be a liner or other intermediate casing string. The casing 12 is arranged within a borehole 18 , which is drilled and completed according to any suitable method known or discovered in the art. The borehole 18 may include vertical as well as deviated or horizontal portions. An annulus 20 is formed between the casing 12 and the borehole 18 . As will be better appreciated in view of the below disclosure, the liner 14 in the illustrated embodiment has a restricted inner diameter in relation to the upper casing string 16 , which disadvantageously affects production and stimulation rates. Namely, as discussed in the Background, it is well established that some minimum radial clearance between the casing and any screen assemblies positioned therein must be maintained in order to support production and/or stimulation at acceptable rates.
After arranging the casing 12 , e.g., hanging or anchoring the liner 14 from or to the casing string 16 , the liner 14 is selectively radially expanded. By selectively expanded, it is meant that portions of the liner 14 are dimensionally enlarged, i.e., plastically deformed, in the radial direction in order to form at least one expanded portion 22 and at least one unexpanded portion 24 . In the illustrated embodiment, a plurality of the expanded portions 22 is interspaced with the unexpanded portions 24 . The liner 14 has an initial drift dimension (e.g., internal diameter) designated D 1 , which drift dimension D 1 is maintained by the unexpanded portions 24 . The expanded portions 22 are radially expanded to an expanded internal dimension (e.g., internal diameter) designated D 2 , which is greater than the internal drift dimension D 1 . The term drift dimension or drift diameter is used with its ordinary meaning in the art, namely, relating to the effective or minimum dimension of the liner 14 , i.e., such that any component smaller than the drift dimension can be run through the tubular (liner, casing, etc.). In accordance with this understood definition, the drift diameter or dimension D 1 may differ slightly from the actual diameter or dimension of the liner 14 . In the illustrated embodiment, the internal dimension D 2 of the expanded portions 22 is less than the diameter of the casing string 16 , while in another embodiment the internal dimension D 2 may exceed the internal diameter of the upper casing string 16 or another section of the casing 12 .
For the purposes of discussion herein, the term expansion is generally interchangeable with swage, deform, enlarge, and other synonyms thereof. Accordingly, the selective expansion of the casing 12 , more specifically of the liner 14 of the casing 12 , can be accomplished by any suitable swage, wedge, cone, or other device that is actuatable or transitionable between a retracted or retractable configuration that enables the device to be run through the liner 14 without deforming the unexpanded portions 24 and a radially extended or supported configuration that enables the expanding device to expand the portions 22 . The actuation or transition between these two configurations could be provided via any suitable mechanism in any suitable manner, e.g., mechanical, hydraulic, electrical, etc. U.S. Pat. No. 6,352,112 (Mills), which patent is incorporated herein by reference in its entirety, provides an example of a selectively supported swage device that could be adapted for selectively expanding the portions 22 of the liner 14 without expanded the unexpanded portions 24 . Those of ordinary skill in the art will recognize that other devices are also suitable for the purpose of selective expansion as described herein. The swaging device could be run into the casing 12 in the same trip as the liner 14 , or a separate trip. The swaging could be performed from bottom-up, from top-down, or combinations thereof for each section desired to be swaged.
It is noted that the timing of the swaging process could be different than that described above. For example, in one embodiment, the swaging or expansion of the liner 14 occurs at surface before, or simultaneously with, run-in of the liner 14 as opposed to after it is already set downhole. In one embodiment, the expanded portion is formed by removing wall thickness of the liner 14 , such that the outer dimension remains consistent while the dimensions D 1 and D 2 still differ. Multiple sections of the liner 14 could be coupled together in such an embodiment, e.g., threadedly, to form multiple alternating ones of the portions 22 and 24 . In one embodiment, the expanded and unexpanded portions 22 and 24 are each formed from separate components having different dimensions that are affixed together, e.g., threaded, in order to form the liner 14 , which is then run-into and secured to the upper casing string 16 .
The annulus 20 radially about the casing 12 may be cemented according to any suitable technique, e.g., pumping cement down through the interior of the casing 12 (or another tubular run therewith) and forcing it back up through the annulus 20 , thereby filling the annulus 20 . In one embodiment the cementation occurs after expanding the portions 22 , while in another embodiment, the expansion occurs immediately after pumping the cement before it has a chance to cure and harden. In the illustrated embodiment, a liner lap 25 at the junction between the liner 14 and the casing string 16 is specifically not swaged and forms one of the unexpanded portions 24 . Advantageously, not swaging the liner lap 25 during the selective swaging process improves the hydraulic performance of a cement pumping operation that may occur subsequent to the selective swaging process with respect to if the liner lap 25 were also swaged.
After cementation, a perforation gun or other assembly for forming openings in the liner 14 is positioned with respect to the expanded portions 22 in the liner 14 and triggered in order to form a plurality of perforations 26 through the liner 14 and the cement in the annulus 20 . Any style of perforating gun could be used and delivered downhole in any desired manner, e.g., coiled tubing, wireline, etc. The perforations 26 provide fluid communication between a downhole formation 28 through which the borehole 18 is formed and an interior passageway 30 of the casing 12 . This fluid communication enables fluid, such as hydrocarbons, to be produced from the downhole formation 28 and/or fluid to delivered to the downhole formation 28 , e.g., in order to stimulate, fracture, or treat the formation to facilitate later production therefrom (generally, “stimulate”). It is noted that in other embodiments, particularly those in which cementation is not required, that the liner 14 or other portion of the casing 12 could be pre-arranged with perforations or other openings in order to save time and avoid an additional perforation trip.
Once fluid communication is established, an inner string 34 , e.g., a production string, can be run including one or more screen assemblies 36 . The string 34 and the screen assemblies 36 may resemble a traditional multi-zone frac system or any other system arranged for enabling the stimulation of and/or production from a downhole formation. In the illustrated embodiment, one of the screen assemblies 36 is provided for each of the expanded portions 22 , which may in turn be associated individually with production zones. A packer 38 or other seal device is arranged on the inner string 34 and arranged to engage against each unexpanded portion 24 in order to isolate the screen assemblies 36 and/or their corresponding zones from each other. The screen assemblies 36 are arranged with a filter or mesh 40 , e.g., wire wrap screen, narrow slots, permeable foam, etc., in order to impede the passage of solids, e.g., sand, therethrough while permitting fluid flow. The screen assemblies 36 can each be provided with a first valve 42 arranged for enabling selective fluid communication directly with the formation 28 (bypassing the filter or mesh 40 ), e.g., in order perform a treatment, stimulation, fracturing, or other operation on the formation 28 , and a second valve 44 arranged for enabling selective fluid communication through the mesh or filter 40 of the screen assemblies 36 , e.g., in order to produce fluid from the formation 28 as well as create a circulation flow path for a gravel or frac pack or other stimulation or treatment operation. The valves 42 and 44 can be opened and/or closed due to hydraulic pressure, engagement with a shifting tool, a dropped plug or ball, or in any other desired manner or combinations thereof.
As noted above, fluid production and stimulation rates of a downhole completion are limited by the size, e.g., diameter, of the screen assemblies used. That is, smaller screens are associated with smaller base pipes and/or production strings having relatively restricted internal flow passages therethrough, which restricts fluid flow for production and stimulation. Furthermore, a minimum radial clearance, as noted above, between the outside of the screen assembly and the inner drift dimension of the casing must be maintained in order to support acceptable stimulation and/or production rates. Advantageously, with specific reference to the system 10 , the swaging of the portions 22 of the liner 14 at which the screen assemblies 36 are positioned, enables the outer dimension (e.g., outer diameter) of the screen assemblies, designated D 3 in FIG. 5 , to approximate or approach the internal drift diameter D 1 of the liner 14 and the unexpanded portions 24 , while still providing the required radial clearance between the screen assemblies and the casing. By the outer dimension D 3 “approximating” the internal dimension D 1 it is not meant that the outer dimension D 3 is some arbitrary amount from the internal dimension D 1 , but is rather meant that the outer dimension D 3 is either at or sufficiently close to the drift dimension D 1 so that the aforementioned necessary minimum radial clearance between the screen assemblies 36 and the liner 14 cannot maintained. However, the dimensions D 1 and D 3 may differ slightly, e.g., due to manufacturing tolerances, to accommodate seal elements (e.g., the packers 38 ), to facilitate run-in of the screen assemblies 36 , etc. In accordance to the above, a gap or clearance 46 is shown in FIG. 5 , formed as the difference between the dimension D 3 of the screen assemblies 36 and the dimension D 2 of the expanded portions 22 . It is to be appreciated that the Figures are not shown proportionally and that the clearance 46 may be several times or even orders of magnitude larger than the difference between the dimensions D 1 and D 3 . By the dimension D 3 of the screen assemblies 36 approximating the dimension D 1 , the necessary radial clearance 46 between the screen assemblies 36 and the unexpanded portions 24 of the liner 14 is not be maintained, and acceptable production and stimulation rates are only supported by positioning the screen assemblies 36 radially proximate to the expanded portions 22 . In one embodiment, the radial clearance 46 is about at least 0.5 inches, as radial clearances of significantly smaller sizes are not typically tolerated in the downhole industry.
An alternate embodiment, designated as a system 10 ′, is shown in FIG. 6 . In this embodiment, the liner 14 is swaged such that two zones or areas are associated with the same swaged portion, designated as a swaged portion 22 ′. In such an embodiment, if isolation is desired between adjacent screen assemblies, e.g., screen assemblies 36 a and 36 b , then a packer 38 ′ is required that is larger than the packers 38 . For example, the packer 38 ′ could be swellable in response to a fluid such as water or oil, inflatable, radially extendable due to axial compression or removal of a retaining band, etc., in order to transition from a first size suitable to bypass the unexpanded portions 24 and yet still be able to engage with the expanded portion 22 ′.
In view of the foregoing, it is to be appreciated that the current invention is particularly advantageous for gravel and frac pack systems, and other systems for which the industry mandates a sufficient radial clearance (e.g., about half an inch or larger) between the screen assemblies and the outer tubular or casing housing the screen assemblies. Even more particularly to systems similar to those illustrated in which screen assemblies are positioned in a relatively smaller dimensioned string, e.g., the liner 14 , which is hung or suspended from a relatively larger dimensioned upper string, e.g., the upper casing 16 . That is, the relatively smaller dimensioned string, e.g., the liner 14 , in which the screen assemblies are placed would typically result in either the size of the screen assemblies to be reduced or that of the radial gap between the screen assemblies and the inner surface of the casing, but this issue is avoided by the current invention. It is also to be understood that although the current invention is particularly advantageous in such situations, the casing or other outer tubular string may not have a relatively smaller dimensioned string hung from a relatively larger outer dimensioned string. Even in this embodiment, the overall dimension of the casing or outer tubular can be reduced, thereby saving material costs, while still producing at the same rate as a traditional system having a larger outer dimension. That is, the size of the casing or outer tubular only needs to be set as just large enough for the screen assemblies to be located therein without need to accommodate for the radial gap between the screen assemblies and inner dimension of the casing, as the desired radial gap is achieved by the above-described swaging process.
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. | A completion system, including a tubular string initially having an substantially constant first dimension and configured to include at least one unexpanded portion having the first dimension and at least one expanded portion having a second dimension larger than the first dimension. The tubular string has at least one opening therein formed at the at least one expanded portion. At least one screen assembly is included having a third dimension and positioned radially adjacent the at least one expanded portion. A radial clearance is formed between the outer dimension of the at least one screen assembly and the second internal dimension of the at least one second portion of the outer tubular string. A method of completing a borehole is also included. | 4 |
RELATED APPLICATION
This is a continuation of application Ser. No. 09/008,584 filed Jan. 16, 1998 now U.S. Pat. No. 6,395,362, which is a continuation in part of application Ser. No. 08/850,726 filed May 2, 1997 now U.S. Pat. No. 6,306,477, which is a continuation in part of application Ser. No. 08/684,004 filed Jul. 19, 1996 now abandoned.
INTRODUCTION TO THE INVENTION
This invention relates to the installation of decorative coverings. It has been shown in the present inventors first patent U.S. Pat. No. 4,822,658 that carpets having a looped backing can be conveniently installed on a floor by the use of complementary hooked tape. One of the primary ways disclosed in that patent is attaching the tape to the floor at the perimeter and seams (hereinafter “perimeter and seam” installation). The present inventor has also developed an anchor sheet which is described in U.S. patent application Ser. No. 08/684,004 filed Jul. 19, 1996 and continuation-in-part application Ser. No. 08/850,726 filed May 2, 1997 (the specifications of which are herein incorporated by reference). Rather than attaching the carpet directly to a hooked tape attached to the floor, an intermediate thin flexible relatively rigid anchor sheet is provided which gives rigidity and integrity and mass to the overlying pieces of carpet covering. The anchor sheet can be covered in hooks. The carpet has an underlying looped backing for attachment to the hooks. The carpet can be in pieces which overlap the anchor sheet pieces to provide rigidity and strength to the total unit.
The perimeter and seam method and the anchor sheet structure and method can both be used and will both work. However in some circumstances it may be advisable to use a combination of both methods in which a form of anchor sheet provides a stable framework into which either a cushion or a covering material or both can be inserted either attached to the floor by a hook and loop attachment method or as a “free float” within the framework. In these circumstances, the anchor sheet can be a support for a covering unit attached to the anchor sheet by hook and loop as shown in the earlier related cases. Carpet within the framework can then be installed with hook and loop or in a conventional manner, i.e., without hook and loop, by glue down or even by free floating.
In some circumstances the hook tape of a perimeter and seam installation can be the “framework” within which an anchor sheet installation can be made. In this case the anchor sheet may float within the framework created by hook tape attached to a floor. Additional methods of attaching a tape framework and a tape framework construction are disclosed as well as other methods of installing an anchor sheet as a framework, including the use of a form or jig.
BACKGROUND OF THE INVENTION
The need for flexibility in installing floor coverings is well known. Most floor coverings must be cut and fit on site and therefore must be flexible to provide for different physical limitations. In addition subflooring and supporting substrates differ widely in both quality and type, even in new construction. In old construction existing flooring may remain and present problems.
The background to the invention is substantially shown in the present inventor's prior issued patents U.S. Pat. No. 4,822,658 (Apr. 18, 1989, Pacione); U.S. Pat. No. 5,191,692 (Mar. 9, 1993, Pacione); U.S. Pat. No. 5,382,462 (Jan. 17, 1995, Pacione); and U.S. Pat. No. 5,479,755 (Jan. 2, 1996, Pacione). In addition attempts to make structural semi-permanent flooring and wall material incorporating a hook surface is also disclosed in the present inventor's earlier anchor board system U.S. Pat. No. 5,060,443 (Oct. 29, 1991, Pacione); U.S. Pat. No. 5,259,163 (Nov. 9, 1993, Pacione); and U.S. Pat. No. 5,144,786 (Sep. 8, 1992, Pacione).
SUMMARY OF THE INVENTION
A thin rigid but flexible anchor sheet has advantages to stabilize the overlying carpet to provide a relatively rigid subfloor for installation of an overlying carpet. When a resilient backing of cushioning material is attached to or supplied under such anchor sheet, the anchor sheet provides a novel subfloor which has significant advantages over existing underpads.
We have described the anchor sheet as both “flexible” and “rigid”. It is flexible in the sense that over a reasonable length it can bend and in most circumstances can even be rolled with a radius of curvature for example of perhaps 3 or 4 inches unlike for example plywood. It is rigid in the sense that if held at one end it can support itself for instance over a distance of 12-24 inches without drooping unlike a cloth or fabric tape.
It is not commonly appreciated that an underpad, while it provides resiliency, can lead to degradation in the overlying decorative textile surface. This is because the resiliency allows for the carpet to deform when walked upon or when furniture or other items are placed on the carpet. This deformation can, if it is not properly supported from below, result in crushing and eventual deterioration of the carpet structure.
The anchor sheet of this invention has a relatively rigid yet flexible thin sheet material, preferably a plastic or of a polymer material such as a polyester, polycarbonate, polypropylene or even a graphite or other advanced polymer material overlying a resilient cushion. This structure provides a surprising amount of resiliency and cushioning to the carpet. However because the overlying anchor sheet is relatively rigid, the carpet fibres are protected from crushing and therefore the life of the carpet is significantly extended while still appearing to have a sufficient degree of resiliency.
In order to provide the proper degree of resilience in the hooks and the proper degree of rigidity to the sheet, the hooks and sheets may need to be made from, for example, different plastic materials by lamination or coextrusion.
To the inventor's knowledge no person, until disclosed in this and the earlier related applications, has had the relatively unconventional idea of covering a resilient material with a thin flexible relatively rigid sheet material.
Thus the invention comprises in, one aspect, an anchor sheet subfloor comprising a laminate having an upper layer of a relatively thin and flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material.
While not as pronounced, the advantages of a relatively rigid but flexible anchor sheet to create a smooth subfloor and to tie overlying carpet pieces together into a stable mass can to some extent be achieved even without a resilient undercushioning. Thus the invention comprises in another aspect a relatively thin flexible rigid sheet material preferably of plastic or polymer which can be cut and fit on site to fit the contours of a room or other area to be covered to form by itself or in combination with other anchor sheets a free floating smooth subfloor on which can be laid decorative covering pieces.
In another aspect the invention comprises a carpet and subfloor comprising a first layer of relatively resilient cushioning material overlaying the floor. A second layer of a thin flexible rigid polymer material overlaying the first layer and hooks covering at least a portion of the top surface of the second layer and a carpet having an undersurface covered in loops and detachably attached to the hooks covering the second layer to form a coherent stable carpet structure.
In another aspect, the subfloor and structure created by the first resilient layer and the second layer of anchor sheet, can be covered across its surface by perimeter and seam hooked tape so as to allow for installation of a carpet on the subfloor in accordance with the method described in U.S. Pat. No. 4,822,658. In this case the subfloor is actually not attached to the floor directly but is normally “floating” but this may be sufficient, in many installations, to stabilize the carpet.
As previously described, in some circumstances, the anchor sheet can act as a framework for either a carpet or an underpad or both. Thus, in another aspect, the invention covers an anchor sheet, carpet and an underpad combination for installing a carpet or underpad onto a floor comprising an anchor sheet installed along the perimeter of an area to be covered, describing and bounding that area, hook tape attached to the sheet along the perimeter of the upper face of the anchor sheet and a resilient underpad of a height matching the height of the anchor sheet sized to fit within the area bounded by the anchor sheet. A carpet having an underside covered in loops can then be overlaid. The anchor sheet perimeter and the resilient underpad may be either free floating or installed in a conventional manner within the anchor sheet framework.
A more complex anchor sheet framework can also be formed consisting of modular covering units made as disclosed in related application Ser. No. 08/850,726. Thus in another aspect the invention comprises a modular framework for carpet installation comprising a plurality of covering modules having decorative coverings attached to a thin flexible rigid anchor sheet so as to leave exposed overlapping areas of anchor sheet or covering for detachable attachment and interlocking relationship to an adjoining module as disclosed in related application Ser. No. 08/850,726. In this aspect of the invention, the modules are then detachably interlocked to define and enclose an area. Carpet or underpad or carpet and underpad depending upon the height of the framework created, is then cut and fit within the area defined by the covering modules.
As previously mentioned, an anchor sheet subfloor can also be installed within a perimeter bounded by hooked tape, in effect creating a hooked tape framework. In this aspect of the invention, a perimeter of hooked tape is attached to the floor. The tape may be of a form disclosed in, for instance, U.S. Pat. No. 5,382,462 or having a tape with a cushioned backing or a tape with a foundation sheet as disclosed in the present application.
In this aspect of the invention, a thin rigid flexible anchor sheet having an upper surface having a plurality of hooks in which the anchor sheet or anchor sheet and cushion is substantially the same height as the tape can then be cut and fit within the area bounded by the hooked tape to provide for a surface underlayment over which a carpet or other decorative covering having a looped backing can be installed.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, reference being had to the accompanying drawings, wherein:
FIG. 1 shows covering modules and a jig for installation.
FIG. 2 shows the covering modules and jig in the process of installation to a floor.
FIG. 3 shows the next step in installation of the covering module and jig.
FIG. 4 shows the finished covering module framework.
FIG. 5 shows the covering module framework at the commencement of the installation of an inserted cushion or carpet.
FIG. 6 shows the completed covering.
FIG. 7 shows the anchor sheet perimeter arrangement.
FIG. 7A shows another form of anchor sheet perimeter arrangement similar to that shown in FIG. 7 .
FIG. 8 shows another form of anchor sheet perimeter arrangement in which the anchor sheet carries a decorative covering which contains a border pattern.
FIG. 8A shows a completed anchor sheet perimeter arrangement.
FIG. 9 shows a form of anchor sheet upon which is installed a perimeter and seam hook and loop tape arrangement.
FIG. 10 shows a form of tape suitable for use in a perimeter arrangement.
FIG. 11 shows a cross-section of a perimeter arrangement having a hooked tape bounding an area of anchor sheet and an overlying decorative covering.
FIG. 12 shows an arrangement of anchor sheet providing a border.
FIG. 13 shows another border arrangement with anchor sheet and cushion.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 is shown a variety of covering modules 2 and 4 . These are similar to the type of covering modules disclosed in related case Ser. No. 08/850,726. In the case of covering module 2 there is an anchor sheet 6 larger than the decorative covering piece 8 . In the case of covering module 4 there is a decorative covering piece 10 which overlaps the anchor sheet 12 .
Normally the anchor sheet areas would be substantially covered in hooks 14 as shown in only representative detail. The overlapping pieces 10 will have on their undersurface loops (not shown) for attachment to the exposed hooks 14 of anchor sheet, for instance, 6 .
A jig or pattern 16 is also shown in FIG. 1 . Its use will become apparent.
The jig at 16 has corners for instance 18 and 19 which serve to locate the corresponding corners of decorative covering piece 8 at each of the four corners of the jig. Thus the covering modules are separated and appropriately spaced in the desired location. Covering module 4 can then be inserted along the sides of the jig abutting the jig as shown. Loops on the undersurface of covering piece 10 (not shown) will enable the covering piece to be installed in detachable attachment in a manner shown in related case Ser. No. 08/850,726 preferably by the use of a smooth slip cover as disclosed in related U.S. patent application Ser. No. 08/850,726. The slip cover can be a hard smooth piece temporarily inserted. It can then be removed when the pieces are in position and the covering modules will form a framework as shown in FIG. 3, in which pieces 4 and pieces 2 have combined to create a structure. Jig 16 is then removed as shown in FIG. 4 so that the anchor sheet framework now lies upon and circumscribes an area of floor 21 and also an area of hooked anchor sheet 20 which is at a different level than the surface of decorative covering 22 .
As shown in FIG. 5 a decorative covering unit 24 can be inserted into the framework 26 . The unit may be carpet having a looped backing (not shown) in which case the carpet would be detachably attached to hooks 28 in the area shown. Normally the complete area would be covered in hooks but only representative samples are shown.
If desired the floor area 21 could be made level with the hooked area 28 by the use of an anchor sheet of suitable thickness, also covered with hooks or smooth, or by the installation of a pad. The area of floor 21 could be left empty because of the low profile of the hooked area 20 .
FIG. 6 shows the unfinished subunit which is ready to be attached by hooks 30 to other adjoining anchor sheet units or covering modules.
In FIG. 7 is shown another form of anchor sheet perimeter installation in which an anchor sheet 32 is formed having a thin rigid flexible covering 34 preferably formed of a plastic or polymer material as described in related application Ser. No. 08/850,726 preferably of a polypropylene, polycarbonate or polyester material and laminated and bonded thereto is a resilient cushion 36 of polyurethane foam or other similar carpet underpad material. Similar anchor sheet units 32 A and 32 B are placed on the floor in abutting relation and the units may be joined together by a pressure sensitive adhesive hooked tape 38 overlying the seams of the anchor sheets or by plain single-sided pressure sensitive tape. Additional hooked tape 40 is added to the perimeter of the anchor sheet installation to provide for a regular perimeter and seam installation as shown in U.S. Pat. No. 4,822,658. It would be convenient if the tape covering joins 41 line up with carpet seams but if they do not, additional tape can be installed on the anchor sheet 32 to provide for at least seam coverage.
Of course if plain tape is used, then hooked tape will normally have to be installed at the carpet seams. Such tape is normally covered prior to installation. Full coverage could also be provided either by adding more hooked tape or by providing anchor sheet 32 with a flexible sheet pre-manufactured with a complete hook covering.
In FIG. 7A is shown an additional similar form of arrangement which combines a hooked tape 42 to be described later at the perimeter of the room, an underpad or anchor sheet with underpad 44 , an additional anchor sheet with underpad 46 , conventional underpads 48 and 50 and anchor sheets 52 and 54 with resilient cushioning and then tape 56 . Thus a complete resilient underlayment is created which is partly a framework made by tape 42 and anchor sheets 44 , 46 , 52 and 54 within which are contained conventional underpads 48 and 50 . A carpet can then be installed over top of this by perimeter and seam tape using tape 42 and 56 at the perimeter and tape 53 at the seams or by the use of an additional anchor sheet (not shown) to provide for decorative surface covering pieces. As shown in FIG. 8 an additional foundation sheet 58 of a similar material to the anchor sheet can have pre-attached permanently or detachably an anchor sheet 60 having a resilient undercushion 62 . The anchor sheet 60 could be one as shown in related application Ser. No. 08/850,726 having its upper surface substantially covered in hooks 64 . Decorative cover pieces, in this case carpet units 65 , can then be installed in any pattern over the anchor sheet. In the example given in FIG. 8 they are installed in a border pattern. When fully assembled as shown in FIG. 8A such a unit can create a framework within which carpet can be installed in a conventional way, or using hook and loop or perimeter and seam or in a small enough area free floated within the area bounded by the decorative border 66 as shown in FIG. 8 A.
FIG. 9 shows an arrangement similar to FIG. 7 in which there is an anchor sheet and resilient cushion framework 68 on either side of conventional carpet pads 70 . The conventional carpet pads may be free floating or attached to the floor in a conventional manner. Normally if the anchor sheets 68 are on the perimeter of the room and abut, for instance, wall 71 on one side and wall 72 on the other side, the whole structure can be “free floating” in the sense that it is not attached to the floor. Hook tape 74 can be installed at the perimeter. Suspended tape 76 at the seams provides a form of perimeter and seam installation over top of a conventional cushion or a partial anchor sheet and conventional cushion. The carpet or other decorative surface covering has loops on its undersurface at 80 (not shown) for detachable attachment to hooks 81 on tape pieces 74 and 76 .
FIG. 10 shows a form of hook tape that can be used to create a perimeter for the installation of a conventional underpad 87 . This tape has a foundation layer 82 to which is attached the tape 84 having a resilient cushion layer 86 . The tape is hook tape and contains across its surface resilient hooks 88 . It normally would be supplied with a tape covering 90 . The foundation sheet 82 allows for a lip or area so that the hook tape may be stapled or nailed through the sheet 82 or through tape 84 to the floor or it can be installed using double-sided adhesive tape 92 or by hook and loop or by a conventional method.
Another form of tape 94 is also shown having foundation sheets 96 and 98 on both sides of the tape. The tape could be stapled to a floor and within the framework bounded by the tape could be inserted an appropriate underpad which could either be installed in a conventional manner or free floating between the tape and an overlying anchor sheet or an anchor sheet having hooked covering (not shown) could also be installed within the area bounded by the tape.
In FIG. 11 is shown a cross-section of hooked tape 100 having cushion 102 attached to the floor.
If the tape is as shown in FIG. 10 it could have foundation sheet 82 for installation. Anchor sheet 104 with (as shown) or without an attached resilient cushion can then be inserted within the area bounded by hooked tape 100 and a decorative covering 106 having an undersurface covered in loops 107 could be installed across the area created by the hooked tape and anchor sheet.
FIG. 12 shows an arrangement in which an anchor sheet 108 is provided with hooks at least over the exposed area 110 shown and also under carpet pieces 112 and border pieces 114 , 116 and 118 . Border pieces 114 , 116 and 118 may be detachably attached to anchor sheet 108 in a pattern and anchor sheet 108 with such pieces could be sold as a preassembled unit. Such piece could be attached to a floor by pressure sensitive adhesive, with hook and loop or by nailing through sheet 108 . Carpet 112 having a loop backing and a pile surface 120 could then be installed and attached to hooks on anchor sheet 110 .
FIG. 13 shows another arrangement, in which anchor sheet 122 , has a resilient cushion 124 and a carpet covering piece 126 detachably attached to the anchor sheet. A conventional cushion 128 can abut the anchor sheet and cushion and a carpet 130 having a loop backing 132 can be installed over the anchor sheet 122 and cushion 128 .
It will be recognized that within the description of this present case and the related earlier pending cases many variations and permutations and combinations are possible of anchor sheet and tape with or without cushion and with or without installation directly to the floor all of which come within the spirit of the described invention as defined in the attached claims. | An anchor sheet subfloor that includes a laminate having an upper layer of relatively thin flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material. The upper sheet layer can be formed of a plastic or polymer material. In one arrangement, the sheet can be cut and fit within the boundaries of a room and the sheet has sufficient rigidity and mass to remain without distortion or buckling within the room by free floating on the existing floor without substantial attachment to the floor. It can be possible for a sheet to be cut and fit on site to fit the contours of a room to form by itself or in combination with other anchor sheets a free floating smooth subfloor on which can be overlaid decorative covering pieces. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of U.S. patent application Ser. No. 14/701,961 filed May 1, 2015, entitled “Container for Providing Aromatic Sampling and Visualization of Contents” which is currently pending, which is incorporated by reference in its entirety and made part of this specification.
BACKGROUND
[0002] Display containers are known in the prior art. Customers commonly wish to visualize contents contained within a display container, and on some occasions, visualize contents under magnification. Further, prospective purchasers frequently wish to test the aroma of contained contents for suitability, freshness, or other features. For example, customers wishing to purchase tea may wish to inspect leaves and sample the aroma. Further, purchasers of legally available cannabis commonly wish to inspect the botanical product in detail and sample aroma. Such display containers that permit adequate storage, preservation, and presentation of botanical samples, such as cannabis, are not adequately described or available.
SUMMARY
[0003] Aspects of the present invention disclose and describe a container for displaying, visualizing, and aroma sampling botanical materials—such as tea, cannabis, and the like. Aspects of the present invention further disclose a container permitting stabilization and magnification of a portion of a sample material—such as a botanical sample.
DRAWINGS
[0004] FIG. 1 is an exploded perspective view of an embodiment of the present invention.
[0005] FIG. 2 is a top view of an embodiment container body of the present invention.
[0006] FIG. 3 is a bottom view of an embodiment container body of the present invention.
[0007] FIG. 4 is a side elevation view of an embodiment container body of the present invention.
[0008] FIG. 5 is a cross-sectional view taken through line 5 - 5 of FIG. 4 .
[0009] FIG. 6 is a side elevation view of an embodiment lid of the present invention.
[0010] FIG. 7 is a cross-sectional view taken through line 7 - 7 of FIG. 6 .
[0011] FIG. 8 is a perspective view of an embodiment of the present invention.
[0012] FIG. 9 is a perspective view of an embodiment lid of the present invention.
[0013] FIG. 10 is an exploded view of an embodiment of the present invention.
[0014] FIG. 11 is a bottom view of an embodiment container body and embodiment tether.
[0015] FIG. 12 is a perspective view of an embodiment square container body.
[0016] FIG. 13 is a bottom perspective view of an embodiment square container body.
[0017] FIG. 14 is a perspective view of an embodiment round container body.
[0018] FIG. 15 is a bottom perspective view of an embodiment round container body.
[0019] FIG. 16 is a perspective view of an embodiment rectangle container body.
[0020] FIG. 17 is a bottom perspective view of an embodiment rectangle container body.
[0021] FIG. 18 is a perspective view of an embodiment oval cross-section container body.
[0022] FIG. 19 is a bottom perspective view of an embodiment oval cross-section container body.
[0023] FIG. 20 is a perspective view of a first embodiment hexagonal container body.
[0024] FIG. 21 is a bottom perspective view of a first embodiment hexagonal container body.
[0025] FIG. 22 is a perspective view of a second embodiment hexagonal container body.
[0026] FIG. 23 is a bottom perspective view of a second embodiment hexagonal container body.
[0027] FIG. 24 is a perspective view of an embodiment diamond container body.
[0028] FIG. 25 is a bottom perspective view of an embodiment diamond container body.
[0029] FIG. 26 is a perspective view of an embodiment oval container body.
[0030] FIG. 27 is a bottom perspective view of an embodiment oval container body.
[0031] FIG. 28 is a perspective view of an embodiment triangle container body.
[0032] FIG. 29 is a bottom perspective view of an embodiment triangle container body.
DESCRIPTION
[0033] Turning now to FIG. 1 , container 5 comprises, a container body 10 having an interior surface 15 and exterior surface 20 . Container body 10 is shaped to define an open top 25 , a bottom 30 , a front 35 , a back 40 , a first side 42 , a second side 44 , and a plurality of feet 45 . Container body 10 is further shaped to define a perimetrical ridge 50 surrounding said open top 25 . A portion of the container body 10 is shaped to define mounting projection 55 to hold a subject sample such as a botanical sample.
[0034] Lid 60 has an interior lid surface 65 ( FIG. 7 ) and exterior lid surface 70 . Lid 60 is shaped to define a perimeter 75 , and optionally further shaped to define at least one projection 80 disposed on a portion of said exterior surface 70 of said lid 60 . One or more projection 80 functions as a card holder to provide information on the sample within container body. Optionally, projection 80 is omitted and informational material is presented within container body—such as a portion of container body 10 shaped to define a card holder within container body 10 . Lid 60 is further shaped to define a viewing opening 85 . Lid 60 is further shaped to define a recessed area 90 , and further shaped to define a plurality of scent openings 95 within said recessed area 90 . In one example embodiment, scent openings are about 0.125 inches in diameter and arranged in two rows. Removable plug 105 shaped to fit within recessed area 90 forming an airtight seal. In one embodiment, the recessed area and removable plug are omitted, and scent holes are located flush on the surface of lid 60 , and optionally scent hole patency is adjustable.
[0035] Turning to FIG. 7 , Lens 100 disposed to cover said viewing opening 85 . Lens 100 may be affixed to lid 60 by snap fit, or friction fit or adhesively. Lens 100 covers viewing opening 85 . Lens 100 forms an airtight seal between lens 100 and said lid 60 . In a preferred embodiment, lens 100 is adhesively affixed within viewing opening 85 . In one embodiment, lens 100 is a plano-convex lens such as Lens #90-1235 manufactured by J.P. Manufacturing. A variety of lenses may be used such as a 1×, 2×, or 3× magnifier. In an alternative embodiment, the lens is not a magnifier.
[0036] Turning to FIG. 8 , Lid 60 is fitted on the perimetrical ridge 50 of said container body 10 forming an airtight chamber 110 , wherein said plug 105 forms an airtight seal between plug 105 and recessed area 90 of said lid 60 completely sealing chamber 110 . In one embodiment, plug 105 is comprised of soft material such as soft rubber or silicone. Lid 60 is further illustrated by FIG. 9 .
[0037] FIG. 2 illustrates a top view of container body 10 showing interior surface 15 . It should be noted that in one embodiment, corners 115 between container body 10 front 35 , a back 40 , a first side 42 , a second side 44 , are rounded, yet in an alternative embodiment corners may be relatively sharp.
[0038] FIG. 3 illustrates a bottom view of container body 10 showing exterior surface 20 . In one embodiment, bottom 30 is flat, in another embodiment, container body 10 bottom may be convex or concave. In a preferred embodiment, bottom 30 is flat and feet 45 allow container body 10 to be set on a flat resting surface where bottom 30 is not in contact with the flat surface. Mounting recess 66 allows an optional tether 120 to be affixed to the apparatus ( FIGS. 10-11 ). In one embodiment, illustrated by FIGS. 10-11 , tether 120 terminates in eyelet 122 . Eyelet 122 is affixed to container 5 by screw 125 which passes through eyelet 122 and tapped into recess 66 thereby holding eyelet 122 and tether 120 in place. Tether 120 allows apparatus 5 to be carried by tether. Apparatus 5 may be rested on a flat surface with tether 120 in place because feet 45 provide sufficient clearance between the eyelet and the flat resting surface.
[0039] FIG. 4 illustrates a side elevation view illustrating feet 45 and perimetrical ridge 50 .
[0040] FIG. 5 is a sectional view taken through line 5 - 5 of FIG. 4 , illustrating a section of mounting spike 55 and recess 66 within. FIG. 6 is a side elevation view of lid 60 demonstrating exterior lid surface 70 and projection 80 . FIG. 7 is a sectional view taken through line 7 - 7 of FIG. 6 . Lens 100 is shown within viewing opening 85 . In one preferred embodiment, lens 100 is countersunk within viewing opening 85 . In an alternative, lens 100 may be domed above viewing opening 85 . Lens 100 may be mounted on or within viewing opening 85 in any fashion permitting visualization through viewing opening 85 . In one embodiment, lens 100 may be replaced with a window which provides viewing but lacks magnification power.
[0041] In use, a botanical sample, such as a sample of cannabis, is selected and placed within container body 10 . A portion of the sample may be mounted on mounting projection 55 . In one example, the end of mounting projection 55 is relatively sharp and capable of piercing a botanical sample—such as a botanical sample of cannabis. The sample is held on projection 55 due to frictional contact with the sample and aided by the sticky nature of the resin. Lid 60 engages perimetrical ridge 50 container body 10 fastening lid 60 and container body 10 together to form chamber 110 . Plug 105 is inserted within recessed area 90 to seal the plurality of scent openings 95 to make chamber 110 airtight. An identification card, bearing information about the botanical product, may be secured by two projections 80 . Turning to FIGS. 10 and 11 , an optional, tether 120 may be affixed as described above. In one embodiment, such a tether may be a lanyard worn about the neck. In another embodiment, tether 125 may be retractable. Tether 125 may be affixed by other means—screw 125 and eyelet 122 providing only an example. The above example of use applies to container bodies of all shapes described herein, which may or may not include mounting projection 55 . If the container does not include a mounting projection, the botanical sample would rest on the internal surface of the container.
[0042] Container body 10 and lid 60 , and any container body and lid described herein, may be formed by injection molding and comprised of Poly(methyl methacrylate) (PMMA). Alternatively, container body 10 and lid 60 may be comprised of Styrene Acrylonitrile resin (SAN) or polycarbonate plastic. Container body 10 and lid 60 may be comprised of any moldable material. Container body 10 and lid 60 may be transparent, translucent or opaque—depending on the specimen to be contained within.
[0043] Container 5 , and other containers and container bodies described herein, may be used for a variety of purposes. For example the inventive apparatus may be used as an entomological storage display. In an alternative, mounting projection 55 may be outfitted with one or more pins, clips, fasteners, prong holder, or adhesive contacts to prepare and display specimens. Further, the present invention is of use for storage, presentation and display of many other items where magnification of the sample or product is desired. For example, projection 55 may be modified to hold other collectable collectible items such as coins, stamps, or jewelry. It these embodiments, lid 60 will be optional shaped without a recessed area or scent holes, or shaped to provide an opening for ventilation. In one embodiment, lid 60 provides user-adjustable ventilation.
[0044] FIG. 12 illustrates a container body 1210 shaped to define a square having a bottom surface 1230 (illustrated by FIG. 13 ). Lens 1299 is shown within viewing opening 1285 . In one preferred embodiment, lens 1299 is countersunk within viewing opening 1285 . In an alternative, lens 1299 may be domed above viewing opening 1285 . Lens 1299 may be mounted on or within viewing opening 1285 in any fashion permitting visualization through viewing opening 1285 . In one embodiment, lens 1299 may be replaced with a window which provides viewing but lacks magnification power. Lid 1260 fits snugly on container body 1210 forming an airtight seal, defining chamber 1211 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 1290 to seal the plurality of scent openings 1295 to make chamber 1211 airtight.
[0045] FIG. 14 illustrates a round embodiment container body 1410 having a bottom surface 1430 (illustrated by FIG. 15 ). Lens 1499 is shown within viewing opening 1485 . In one preferred embodiment, lens 1499 is countersunk within viewing opening 1485 . In an alternative, lens 1499 may be domed above viewing opening 1485 . Lens 1499 may be mounted on or within viewing opening 1485 in any fashion permitting visualization through viewing opening 1485 . In one embodiment, lens 1499 may be replaced with a window which provides viewing but lacks magnification power. Lid 1460 fits snugly on container body 1410 forming an airtight seal, defining chamber 1411 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 1490 to seal the plurality of scent openings 1495 to make chamber 1410 airtight.
[0046] FIG. 16 illustrates a substantially rectangularly shaped embodiment container body 1610 having a bottom surface 1630 (illustrated by FIG. 17 ). Lens 1699 is shown within viewing opening 1685 . In one preferred embodiment, lens 1699 is countersunk within viewing opening 1685 . In an alternative, lens 1699 may be domed above viewing opening 1685 . Lens 1699 may be mounted on or within viewing opening 1685 in any fashion permitting visualization through viewing opening 1685 . In one embodiment, lens 1699 may be replaced with a window which provides viewing but lacks magnification power. Lid 1660 fits snugly on container body 1610 forming an airtight seal, defining chamber 1611 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 1690 to seal the plurality of scent openings 1695 to make chamber 1611 airtight.
[0047] FIG. 18 illustrates an oval cross-section shaped embodiment container body 1810 having a bottom surface 1830 (illustrated by FIG. 19 ). Lens 1899 is shown within viewing opening 1885 . In one preferred embodiment, lens 1899 is countersunk within viewing opening 1885 . In an alternative, lens 1899 may be domed above viewing opening 1885 . Lens 1899 may be mounted on or within viewing opening 1885 in any fashion permitting visualization through viewing opening 1885 . In one embodiment, lens 1899 may be replaced with a window which provides viewing but lacks magnification power. Lid 1860 fits snugly on container body 1810 forming an airtight seal, defining chamber 1811 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 1890 to seal the plurality of scent openings 1895 to make chamber 1811 airtight.
[0048] FIG. 20 illustrates a first substantially hexagonally-shaped embodiment container body 2010 having a bottom surface 2030 (illustrated by FIG. 21 ). Lens 2099 is shown within viewing opening 2085 . In one preferred embodiment, lens 2099 is countersunk within viewing opening 2085 . In an alternative, lens 2099 may be domed above viewing opening 2085 . Lens 2099 may be mounted on or within viewing opening 2085 in any fashion permitting visualization through viewing opening 2085 . In one embodiment, lens 2099 may be replaced with a window which provides viewing but lacks magnification power. Lid 2060 fits snugly on container body 2010 forming an airtight seal, defining chamber 2011 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 2090 to seal the plurality of scent openings 2095 to make chamber 2011 airtight.
[0049] FIG. 22 illustrates a second substantially hexagonally-shaped embodiment container body 2210 having a bottom surface 2230 (illustrated by FIG. 23 ). Lens 2299 is shown within viewing opening 2285 . In one preferred embodiment, lens 2299 is countersunk within viewing opening 2285 . In an alternative, lens 2299 may be domed above viewing opening 2285 . Lens 2299 may be mounted on or within viewing opening 2285 in any fashion permitting visualization through viewing opening 2285 . In one embodiment, lens 2299 may be replaced with a window which provides viewing but lacks magnification power. Lid 2260 fits snugly on container body 2210 forming an airtight seal, defining chamber 2211 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 2290 to seal the plurality of scent openings 2295 to make chamber 2211 airtight.
[0050] FIG. 24 illustrates diamond-shaped embodiment container body 2410 having a bottom surface 2430 (illustrated by FIG. 25 ). Lens 2499 is shown within viewing opening 2485 . In one preferred embodiment, lens 2499 is countersunk within viewing opening 2485 . In an alternative, lens 2499 may be domed above viewing opening 2485 . Lens 2499 may be mounted on or within viewing opening 2485 in any fashion permitting visualization through viewing opening 2485 . In one embodiment, lens 2499 may be replaced with a window which provides viewing but lacks magnification power. Lid 2460 fits snugly on container body 2410 forming an airtight seal, defining chamber 2411 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 2490 to seal the plurality of scent openings 2495 to make chamber 2411 airtight.
[0051] FIG. 26 illustrates an oval shaped embodiment container body 2610 having a bottom surface 2630 (illustrated by FIG. 27 ). Lens 2699 is shown within viewing opening 2685 . In one preferred embodiment, lens 2699 is countersunk within viewing opening 2685 . In an alternative, lens 2699 may be domed above viewing opening 2685 . Lens 2699 may be mounted on or within viewing opening 2685 in any fashion permitting visualization through viewing opening 2685 . In one embodiment, lens 2699 may be replaced with a window which provides viewing but lacks magnification power. Lid 2660 fits snugly on container body 2610 forming an airtight seal, defining chamber 2611 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 2690 to seal the plurality of scent openings 2695 to make chamber 2611 airtight.
[0052] FIG. 28 illustrates a first substantially triangle embodiment container body 2810 having a bottom surface 2830 (illustrated by FIG, 29 ). Lens 2899 is shown within viewing opening 2885 . In one preferred embodiment, lens 2899 is countersunk within viewing opening 2885 . In an alternative, lens 2899 may be domed above viewing opening 2885 . Lens 2899 may be mounted on or within viewing opening 2885 in any fashion permitting visualization through viewing opening 2885 . In one embodiment, lens 2899 may be replaced with a window which provides viewing but lacks magnification power. Lid 2860 fits snugly on container body 2810 forming an airtight seal, defining chamber 2811 . Plug 105 , illustrated by FIGS. 1, 8, and 10 , is inserted within recessed area 2890 to seal the plurality of scent openings 2895 to make chamber 2811 airtight.
[0053] For illustrative purposes, mounting projection 55 , described above, has not been shown in FIGS. 12-28 , however, in one embodiment, any container body described herein may be shaped to define mounting projection 55 to hold a subject sample such as a botanical sample.
[0054] All lenses described in this patent application may be disposed to cover said viewing opening. Lenses may be affixed to lid 60 by snap fit, or friction fit or adhesively. Lenses forms an airtight seal between lenses and lids of various embodiments. Lenses described herein may be plano-convex lens such as Lens #90-1235 manufactured by J.P. Manufacturing. A variety of lenses may be used such as a 1×, 2×, or 3× magnifier. In an alternative embodiment, the lens is not a magnifier.
[0055] Any of the container bodies described herein may be shaped to define feet 45 as described. Any lid described herein may be shaped to define a card holder.
[0056] Tether 120 may be optionally incorporated with any embodiment container as described above.
[0057] All container bodies described herein a have an interior surface and exterior surface. All container bodies are shaped to define an open top and a bottom. All container bodies described herein are shaped to define a perimetrical ridge surrounding the open top. Further, all container bodies may be further shaped to define a mounting projection disposed on the interior of said bottom of the container bodies. In some embodiments, a container body may not be shaped to define a mounting projection, and is simply flat.
[0058] All lids described herein have an interior surface and exterior surface, wherein the lids are shaped to define a perimeter, wherein lids are shaped to define a viewing opening. All lids described herein are further shaped to define a recessed area and shaped to define a plurality of scent openings within the recessed area.
[0059] A removable soft plug may be used with all lids described herein, and shaped to fit within the recessed area forming an airtight seal.
[0060] For any given container body shape, the perimeter of the lid will correspond to the perimetrical ridge of the container body, such that the lid is fitted on the perimetrical ridge of said container body forming a chamber. The plug forms an airtight seal between said plug and said lid completely sealing a chamber of any shaped described herein.
[0061] Although the present invention has been described with reference to the preferred embodiments, it should be understood that various modifications and variations can be easily made by those skilled in the art without departing from the scope and spirit of the invention. Accordingly, the foregoing disclosure should be interpreted as illustrative only and is not to be interpreted in a limiting sense. It is further intended that any other embodiments of the present invention that result from any changes in application or method of use or operation, which are not specified within the detailed written description or illustrations contained herein yet, are considered apparent or obvious to one skilled in the art are within the scope of the present invention. Further, it should be noted that several inventive embodiments and features are disclosed together for convenience; unless specified otherwise, all embodiment inventive options disclosed herein may be used independently from each other or cooperatively together. Use of distinct reference characters is for illustrative purposes only, and the illustrated embodiment or feature may be used either cooperatively with or distinctly from any other embodiment or feature unless specified otherwise. | Aspects of the present invention disclose and describe embodiment containers for displaying, visualizing, and aroma sampling botanical materials—such as tea, cannabis, and the like including a container body, lid, and lens—which may have various shapes. In a preferred embodiment, lid is shaped to define a recessed area with scent openings permitting aroma sampling of a sample contained within. A removable plug is shaped to fit within the recessed area of the lid. The container body and lid, with removable plug fit within the lid, form an airtight chamber within. A botanical sample may be visualized through the lens. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a technique of using a plasma generator to purify exhaust gas discharged from an internal combustion engine.
[0003] 2. Description of the Related Art
[0004] There is proposed a method of using plasma for an exhaust gas purifying technique of a lean burn engine (mainly Diesel engine). The method of using the plasma is a technique in which electromagnetic energy is imparted to the exhaust gas by discharge to put the exhaust gas into a plasma state, and thereby decomposition reaction of toxic substances is promoted to generate a direct purification reaction or a purification reaction with a catalyst or the like (for example, see Japanese Patent Publication Laid-Open No. H6-10652).
[0005] Usually a method in which the alternating current discharge is utilized to generate the plasma, and there are proposed many techniques of controlling the plasma conditions improve purification efficiency (for example, see Japanese Patent Publication Laid-Open Nos. H5-59934 and 2001-46910).
[0006] Japanese Patent Publication Laid-Open No. H5-59934 discloses a configuration in which corona discharge is applied to the exhaust gas of the internal combustion engine to perform denitration. In the configuration, discharge voltage to an electrode which performs the corona discharge is controlled according to an operation condition of the internal combustion engine.
[0007] Japanese Patent Publication Laid-Open No. 2001-46910 discloses a technique of controlling an interval of the intermittent discharge corresponding to an exhaust gas flow rate in a configuration in which high alternating-current voltage is applied to the internal combustion engine exhaust gas to perform the intermittent discharge. These techniques are aimed at the improvement of exhaust gas purification efficiency and reduction of electric power consumption.
[0008] However, in the conventional techniques, there is a limitation to pursuance of the purification efficiency without largely increasing the electric power consumption. That is, the pursuance of the purification efficiency inevitably leads to the increase in electric power consumption.
SUMMARY OF THE INVENTION
[0009] In view of the foregoing, an object of the invention is to provide a technique of enhancing the purification efficiency while the increase in electric power consumption is suppressed in the technique of utilizing the discharge to purify the exhaust gas.
[0010] A first aspect of the invention is an exhaust gas purifying apparatus which purifies exhaust gas of an internal combustion engine, the exhaust gas purifying apparatus including a pair of discharge electrode which applies voltage to exhaust gas; voltage control means for controlling a waveform of voltage supplied to the discharge electrode; and detection means for detecting a load on an internal combustion engine, an exhaust gas flow rate, and purification reaction efficiency, wherein a waveform of the voltage has a burst period including a discharge period and an undischarged period, a predetermined basic waveform periodically existing in a repeated manner in the discharge period, the discharge being not performed in the undischarged period, and the voltage control means responds to output of the detection means to adjust an amplitude, a period, and a continuous iteration count of the basic waveform and a length of the burst period.
[0011] For example, the load on the internal combustion engine is detected by detecting the concentration of PM (Particulate Matter, for example, soot) included in the exhaust gas discharged from the internal combustion engine. In this case, it is determined that the high load is applied on the Diesel engine when the PM concentration is high, and it is determined that the low load is applied on the Diesel engine when the PM concentration is low. Alternatively, a method of detecting the exhaust gas concentration and a method of detecting a torque load on the internal combustion engine can be cited as an example of the method of detecting the load.
[0012] The purification reaction efficiency shall mean purification efficiency of the purifying target substance which is obtained as a result of the discharge to the exhaust gas. The PM removal efficiency can be cited as an example of the purification reaction efficiency.
[0013] The terminology used in the specification will be described below. The basic waveform shall mean a minimum unit of waveform which does not include two or more waveforms having periodicities in itself, and the basic waveform is defined by a one-period waveform having the periodicity such as a sine wave, a rectangular wave, a triangular wave, and a pulse wave. FIG. 1 is a conceptual view explaining the discharge waveform utilized. In FIG. 1 , the basic waveform designated by the numeral 101 is illustrated as the minimum unit of waveform.
[0014] The discharge period shall mean a period during which the basic waveform is continuously repeated as a unit of one period. The undischarged period shall mean a period during which the discharge is not performed. For example, FIG. 1 shows the discharge period during which the iteration count of the basic waveform 101 is five times and the discharged period during which the iteration count is three times.
[0015] The burst period is defined by a period including the one-time discharge period and the subsequent undischarged period. A length ratio of the discharge period and the undischarged period can arbitrarily be adjusted. For example, in the state in which the burst period is fixed, when the discharge period is lengthened, the undischarged period is shortened. The basic waveform iteration count shall mean the number of times in which the one-period basic waveform is continuously repeated.
[0016] In the first aspect of the invention, the load on the internal combustion engine, the exhaust gas flow rate, and the purification reaction efficiency are detected, and the amplitude, the period, and the continuous iteration count of the basic waveform and the length of burst period are adjusted based on the detection values.
[0017] As described later, in the intermittent discharge in which the discharge period and the undischarged period are combined, the purification efficiency can be improved by increasing the discharge voltage (basic waveform amplitude). Furthermore, at this point, the purification efficiency can be enhanced while the increase in electric power consumption is suppressed by decrementing the basic waveform iteration count. That is, the discharge voltage is increased and the discharge period is shortened, which allows the purification efficiency to be enhanced without increasing the electric power consumption.
[0018] The increase in discharge voltage produces an effect of enhancing the instantaneous discharge energy to increase discharge density. A method of increasing an iteration frequency of the basic waveform (method of shortening the basic waveform period) can also be adopted as the method of enhancing the discharge density.
[0019] As described later, the purification efficiency of the toxic substance can be pursued while the electric power consumption is suppressed by optimizing the burst period.
[0020] Thus, the removal efficiency of the toxic substance in the exhaust gas is compatible with the suppression of the electric power consumption by adjusting the amplitude, the period, and the continuous iteration count of the basic waveform and the length of burst period.
[0021] A second aspect of the invention is an exhaust gas purifying apparatus which purifies exhaust gas of an internal combustion engine, the exhaust gas purifying apparatus including a pair of discharge electrode which applies voltage to exhaust gas; voltage control means for controlling a waveform of voltage supplied to the discharge electrode; and detection means for detecting a load on an internal combustion engine, an exhaust gas flow rate, and purification reaction efficiency, wherein a waveform of the voltage has a burst period including a discharge period and an undischarged period, a predetermined basic waveform periodically existing in a repeated manner in the discharge period, the discharge being not performed in the undischarged period, and the voltage control means controls: (1) an amplitude and/or a period of the basic waveform according to the load on the internal combustion engine; (2) a continuous iteration count of the basic waveform according to the purification reaction efficiency; and (3) the burst period according to the exhaust gas flow rate.
[0022] There are various parameters which have an influence on the purification efficiency. In the case where the purification efficiency is simply pursued, the input electric power is also increased according to the purification efficiency. According to the second aspect of the invention, the purification efficiency can be pursued while the increase in input electric power is suppressed by properly selecting the target which should be controlled according to the sensed physical value. That is, in the second aspect of the invention, when the load on the internal combustion engine is increased, the basic waveform amplitude is increased and/or the basic waveform period is shortened, and thereby the discharge energy density is increased. Therefore, the decrease in purification efficiency can be suppressed in association with the increase in load. When the load on the internal combustion engine is decreased, it is necessary that the basic waveform amplitude be decreased and/or the basic waveform period be lengthened.
[0023] The purification reaction efficiency is monitored, and the basic waveform iteration count is incremented when the purification reaction efficiency is decreased to a predetermined value. In this case, because the discharge period is lengthened in the burst period, the discharge is applied to the exhaust gas for a longer time. That is, when the purification reaction efficiency is decreased, the basic waveform iteration count is incremented to suppress the decrease in discharge efficiency. In this case, because the undischarged period during which the discharge is not performed exists after the discharge period during which the basic waveform is repeated, the purification efficiency can be secured while the input electric power is saved. When the purification efficiency exceeds a predetermined value, it is necessary to decrement the basic waveform iteration count.
[0024] The meaning that the basic waveform iteration count is adjusted according to the purification efficiency will be described below. The purification efficiency can also be enhanced by adjusting the voltage of the basic waveform. However, it is not proper to excessively increase the basic waveform due to a restriction of power supply voltage or a restriction of withstanding voltage of an oscillation system device. In the invention, a role is divided such that the basic waveform voltage is adjusted according to the loaded condition while the necessary reaction efficiency is adjusted by the basic waveform iteration count. Thus, in the restriction of the power supply voltage or the restriction of the withstanding voltage of the oscillation system device, the high purification efficiency can be obtained while the low electric power consumption is pursued.
[0025] The exhaust gas flow rate is monitored, and the burst period is shortened when the exhaust gas flow rate is increased. Therefore, the discharge electric power density per unit time can be increased to respond to the increase in exhaust gas flow rate. When the exhaust gas flow rate is decreased, it is necessary to lengthen the burst period.
[0026] For example, it is also possible to respond to the increase in exhaust gas flow rate by the method of increasing the discharge voltage, the method of increasing the iteration frequency of the basic waveform, and the method of incrementing the basic waveform iteration count. However, as described above, because there is the limitation to the increase in basic waveform voltage, it is not proper to increase the basic waveform voltage to respond to the increase in exhaust gas flow rate. Because the iteration frequency of the basic waveform is restricted by a composition and pressure of a discharge atmosphere from the need to stably perform the discharge, it is also not proper to increase the iteration frequency of the basic waveform according to the flow rate. Because the excessive increment of the basic waveform iteration count leads to the decrease in undischarged period, form the viewpoint of pursuance of the low electric power consumption, it is not preferable that the basic waveform iteration count be excessively incremented. Accordingly, it is preferable to change the burst period to deal with the increase in exhaust gas flow rate.
[0027] Thus, both the purification efficiency and the low electric power consumption can be pursued by limiting the parameter according to the sensed parameter.
[0028] An example of the discharge waveform used in the invention will briefly be described below. FIG. 2 is a conceptual view showing an example of the discharge waveform. FIG. 2A shows the basic waveform having the iteration count of twice.
[0029] For example, in the low loaded condition, it is assumed that the discharge is performed with the discharge waveform shown in FIG. 2A . In this state of things, it is assumed that the load is increased to increase the exhaust gas flow rate. For the increase in load, the control is performed such that the iteration frequency of the basic waveform is increased while the basic waveform voltage (amplitude) is increase. For the increase in exhaust gas flow rate, the control is performed such that the burst period is shortened.
[0030] FIG. 2B shows an example of the discharge waveform after the control is performed to the discharge waveform shown in FIG. 2A . When compared with the discharge waveform shown in FIG. 2A , the discharge waveform shown in FIG. 2B is set such that the basic waveform voltage is increased while the basic waveform period is shortened. The burst period is also shortened.
[0031] It is considered that the load is further increased from the state shown in FIG. 2B . In this case, the control is performed such that the iteration frequency of the basic waveform is further increased while the basic waveform voltage (amplitude) is further increase. FIG. 2C shows the discharge waveform which is outputted by performing the control. When compared with the discharge waveform shown in FIG. 2B , the discharge waveform shown in FIG. 2C is set such that the basic waveform voltage is increased while the basic waveform period is shortened.
[0032] In the first aspect or second aspect of the invention, an exhaust gas purifying apparatus may include electrode temperature detection means for detecting a temperature of the discharge electrode, wherein the voltage control means controls the continuous iteration count of the basic waveform and the burst period according to the temperature of the discharge electrode.
[0033] For example, when the continuous use of the plasma or excessive injection of the discharge energy is generated, the temperature of the discharge electrode is raised. When the temperature of the discharge electrode is raised, a rate of thermionic emission is increased, and there is a strong tendency to consume the discharge energy in the form of heat. Therefore, the removal efficiency of the toxic substance is decreased.
[0034] Accordingly, the discharge electrode temperature is monitored, and the continuous iteration count of the basic waveform is decremented and/or the burst period is lengthened when the temperature is raised with respect to the steady state. This enables the energy high-density state to be maintained in the discharge period. On the other hand, the undischarged period is relatively lengthened, and the lengthened undischarged period becomes a cooling period to suppress the temperature rise of the discharge electrode.
[0035] The temperature is raised in a space between the discharge electrodes as the temperature of the discharge electrode is raised. As a result, a difference in gas temperature between the pre-plasma process and the post-plasma process is increased compared with the steady state. For example, the method of detecting the temperature of the discharge space (plasma generation vessel) and the method of detecting the difference in gas temperature between the pre-plasma process and the post-plasma process can be cited as an example of the method of detecting the discharge electrode temperature.
[0036] The discharge electrode temperature can be actively controlled by utilizing this mode. For example, in the case where an exothermic reaction of a plasma reaction component is locally generated in a concentrated manner or in the case where the exhaust gas temperature is rapidly raised, the discharge electrode temperature is rapidly raised, and sometimes the discharge leads to an arc discharge. The arc discharge is not suitable to the exhaust gas purification, because plasma generation efficiency becomes worsened to induce the decrease in purification efficiency. In this case, the continuous iteration count of the basic waveform and the burst period are controlled according to the discharge electrode temperature, which allows the discharge electrode temperature to be adjusted at a predetermined appropriate temperature. This enables the electrode temperature suitable for the effective discharge to be set.
[0037] According to the invention, the removal efficiency of the toxic substance in the exhaust gas is compatible with the suppression of the electric power consumption by adjusting the amplitude, the period, and the continuous iteration count of the basic waveform and the length of burst period.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a conceptual view explaining a discharge waveform utilized in the invention;
[0039] FIG. 2 is a conceptual view explaining types of the discharge waveform utilized in the invention;
[0040] FIG. 3 is a block diagram showing an example of an exhaust gas purifying system in which the invention is utilized;
[0041] FIG. 4 is a conceptual view showing an example of a plasma generator;
[0042] FIG. 5 is a flowchart showing an operation example of the exhaust gas purifying system shown in FIG. 3 ;
[0043] FIG. 6 shows data of a PM purification ratio in each example; and
[0044] FIG. 7 is a data plot showing a relationship between a burst period and the PM purification ratio.
DESCRIPTION OF THE PREFERRED EMBODIMENT
(1) Embodiment
[0000] (Configuration of Embodiment)
[0045] An example in which an exhaust gas purifying apparatus according to the invention is applied to a system for removing PM (Particulate Matter, the soot is the target in this case) contained in the exhaust gas of the Diesel engine will be described below.
[0046] FIG. 3 is a block diagram showing an example of an exhaust gas purifying system in which the invention is utilized. A Diesel engine 301 , a PM concentration sensor 302 , a flow rate sensor 303 , a plasma generator 304 , a PM concentration sensor 305 , a loaded condition computing device 306 , a reaction efficiency computing device 307 , a voltage control device 308 , and a temperature sensor 309 are shown in FIG. 3 .
[0047] An automobile engine, a truck engine, a bus engine, a railroad vehicle engine, a shipping engine, and a power generator engine can be cited as an example of Applications of the Diesel engine 301 . In the embodiment, the exhaust gas discharged from the Diesel engine 301 flows sequentially through the PM concentration sensor 302 , the flow rate sensor 303 , the plasma generator 304 , and the PM concentration sensor 305 . The exhaust gas flowing out from the PM concentration sensor 305 is discharged to an environment through a catalyst converter or a silencer (not shown).
[0048] The PM concentration sensor 302 detects a PM concentration in the exhaust gas discharged from the Diesel engine 301 before the exhaust gas enters the plasma generator 304 . The PM concentration sensor 302 sends the detection value of the PM concentration to the loaded condition computing device 306 and the reaction efficiency computing device 307 . The flow rate sensor 303 detects a flow rate of the exhaust gas discharged from the Diesel engine 301 , and the flow rate sensor 303 sends the detection value of the exhaust gas flow rate to the voltage control device 308 .
[0049] The plasma generator 304 has a basic structure shown in FIG. 4 , the plasma generator 304 performs the discharge to the exhaust gas to put the exhaust gas into the plasma state, and the plasma generator 304 decomposes PM to purify the exhaust gas. In the action of the embodiment, the exhaust gas is put into the ionized state or activated state, and the soot included in the exhaust gas is changed to carbon monoxide or carbon dioxide. Therefore, the soot existing in the exhaust gas can be purified.
[0050] The plasma generator 304 is controlled by the voltage control device 308 . The voltage control device 308 controls a discharge voltage (basic waveform amplitude), an iteration count of a basic waveform, a basic waveform period (iteration frequency) and a burst period. The PM concentration sensor 305 detects the PM concentration in the exhaust gas which passes through the plasma generator, and the PM concentration sensor 305 sends the detection value of the PM concentration to the reaction efficiency computing device 307 .
[0051] The loaded condition computing device 306 computes a loaded condition of the Diesel engine 301 based on the PM concentration detected by the PM concentration sensor 302 . At this point, it is determined that the high load is applied on the Diesel engine 301 when the PM concentration is high, and it is determined that the low load is applied on the Diesel engine 301 when the PM concentration is low. The loaded condition computing device 306 includes a memory in which a data table is stored. A relationship between the PM concentration and the loaded condition is determined by the data table. The loaded condition is computed from the detected PM concentration using the data table.
[0052] The reaction efficiency computing device 307 compares the PM measurement value of the PM concentration sensor 302 and the PM measurement value of the PM concentration sensor 305 to compute PM purification efficiency in the plasma generator 304 . The reaction efficiency computing device 307 sends the computation result to the plasma generator 304 .
[0053] The voltage control device 308 controls discharge conditions of the plasma generator 304 . The voltage control device 308 performs the controls based on the loaded condition computed by the loaded condition computing device 306 , the reaction efficiency computed by the reaction efficiency computing device 307 , the exhaust gas flow rate outputted from the flow rate sensor 303 , and electrode temperature detected by the temperature sensor 309 . Contents of the control will be described later.
[0054] The voltage control device 308 includes CPU (not shown), a memory (not shown), and an interface (not shown). CPU controls the operation of the later-described contents. A program and various kinds of data are stored in the memory. The interface conducts communication with other devices. The program for determining a processing procedure in the control and the data necessary for the various kinds of control are stored in the memory. That is, the data table for determining the relationship among the loaded condition (or PM concentration), the discharge voltage, and the discharge period, the data table for determining the relationship between the reaction efficiency and the iteration count of the basic discharge waveform, the data table for determining the relationship between the exhaust gas flow rate and the burst period, the data table for determining the relationship among the electrode temperature, the burst period, and the iteration count of the basic discharge waveform are stored in the memory of the voltage control device 308 . The data contents in which the optimum combinations are previously determined by experiments are used as the contents of the data table.
[0055] The temperature sensor 309 detects the electrode temperature of the plasma generator 304 , and the temperature sensor 309 sends the detected data to the voltage control device 308 . In the embodiment, the temperature sensor 309 detects the temperature of one of the discharge electrodes as the electrode temperature of the discharge electrode.
[0056] FIG. 4 is a conceptual view showing an outline of the plasma generator 304 of FIG. 3 . The plasma generator 304 shown in FIG. 4 includes a positive electrode 401 , a negative electrode 402 , a positive electrode 403 , alumina plates 404 and 405 , discharge spaces 406 and 407 , a voltage generator 408 , and the temperature sensor 309 .
[0057] In the plasma generator 304 , the pair of positive electrodes 401 and 403 is arranged so as to sandwich the negative electrode 402 . The negative electrode 402 is connected to a ground potential, and the positive electrodes 401 and 403 are connected to the voltage generator 408 .
[0058] The discharges are generated in a discharge space 406 between the positive electrode 401 and the negative electrode 402 and in a discharge space 407 between the positive electrode 403 and the negative electrode 402 . The exhaust gas flows in the discharge spaces 406 and 407 toward a direction shown by arrows 409 , and the discharge is imparted to the exhaust gas in the discharge spaces 406 and 407 . PM (in this case, the target is the soot) included in the exhaust gas is decomposed to purify PM by imparting the discharge to the exhaust gas.
[0059] The alumina plates 404 and 405 are arranged over a surface of the positive electrode 401 facing the discharge space 406 and over a surface of the negative electrode 402 facing the discharge space 407 respectively. An abnormal discharge such as an arc discharge can be prevented to realize the stable discharge by arranging the dielectric material such as alumina over the surface on the discharge space side of the electrode.
[0060] The voltage generator 408 is controlled by the voltage control device 308 . In the embodiment, the voltage generator 408 generates the later-described voltage waveform to supply the voltage waveform to the discharge electrode (positive electrode 401 and negative electrode 402 ). The target to be controlled includes the amplitude and period (frequency) of the basic waveform, a continuous iteration count of the basic waveform, and the burst period. The temperature sensor 309 detects the temperature of the positive electrode 403 , and the temperature sensor 309 sends the detection signal to the voltage control device 308 .
[0000] (Operation of Embodiment)
[0061] FIG. 5 is a flowchart showing an operation example of the exhaust gas purifying system shown in FIG. 3 . When the control of the plasma generator 304 is started, the loaded condition of the Diesel engine 301 is obtained (Step S 501 ). In the embodiment, the PM concentration included in the exhaust gas of the Diesel engine 301 is measured by the PM concentration sensor 302 , and the loaded condition is computed based on the measurement value of the PM concentration. In this case, the loaded condition is obtained such that the high load is applied on the Diesel engine 301 when the PM concentration is high and the low load is applied on the Diesel engine 301 when the PM concentration is low.
[0062] When the loaded condition is obtained, the data table stored in the memory of the voltage control device 308 is referred to, and the discharge voltage and the discharge period are read according to the loaded condition detected in Step S 501 . The signals indicating the read discharge voltage and discharge period are sent from the voltage control device 308 to the plasma generator 304 . Thus, the discharge voltage and the discharge period are adjusted according to the loaded condition (Step S 502 ).
[0063] In Step S 502 , in the case of the large load (in the case of the high PM concentration), the control is performed such that the discharge voltage is increased to shorten the discharge period (discharge period of basic waveform).
[0064] Then, the reaction efficiency in the plasma generator 304 is obtained (Step S 503 ). The reaction efficiency computing device 307 compares the detection values of the PM concentrations of the PM concentration sensors 302 and 305 to obtain the reaction efficiency. At this point, the reaction efficiency is increased as the PM concentration detected by the PM concentration sensor 305 becomes lower compared with the PM concentration detected by the PM concentration sensor 302 . The basic discharge waveform iteration count corresponding to the obtained reaction efficiency is read from the memory, and the signal indicating the basic discharge waveform iteration count is sent from the voltage control device 308 to the plasma generator 304 . Thus, the basic discharge waveform iteration count is adjusted based on the reaction efficiency (Step S 504 ).
[0065] Then, the exhaust gas flow rate is detected with the flow rate sensor 303 (Step S 505 ). The burst period is read from the memory in the voltage control device 308 according to the detected exhaust gas flow rate, and the signal indicating the burst period is sent from the voltage control device 308 to the plasma generator 304 . Thus, the burst period is adjusted according to the exhaust gas flow rate (Step S 506 ).
[0066] In Step S 506 , the adjustment is performed such that the burst period is shortened when the exhaust gas flow rate is increased while the burst period is lengthened when the exhaust gas flow rate is decreased.
[0067] The temperature of the positive electrode 403 is detected with the temperature sensor 309 (Step S 506 ), and the burst period and the basic discharge iteration count are adjusted based on the detected temperature (Step S 507 ). At this point, in the case the electrode temperature is raised, the adjustment is performed such that the burst period is lengthened while the basic discharge iteration count is decreased. In the case the electrode temperature is decreased, the reverse adjustment is performed.
[0068] It is determined whether or not the control is ended (Step S 508 ). When the control is ended, the operation is ended. When the control is not ended, the flow returns to Step S 501 .
(2) Experimental Result
[0069] In the case where the invention is utilized for removing PM (soot in this case) from the exhaust gas, the result that examines the effect will be described below. In this case, the data is collected with the system shown in FIG. 3 .
[0070] The conditions on which the data is obtained are as follows. A water-cooled four-cycle Diesel (three cylinders) is used as the Diesel engine 301 . In the water-cooled four-cycle Diesel, a total displacement is 1061 cm 3 , use fuel is Diesel light oil, and rated power is 12 kVA.
[0071] The amount of PM in the exhaust gas is measured by a gravimetric method in which PM is collected by a filter (not shown). That is, a predetermined amount of exhaust gas is sampled to collect PM with a commercially available filter (0.3 μm mesh), and a difference in weight before and after the collection is set at the PM weight.
[0072] In this case, the positive electrodes 401 and 404 and the negative electrode 402 for formed by a stainless plate having a thickness of 1.0 mm and a size of 20 mm by 50 mm. The alumina plates 404 and 405 have the thickness of 0.5 mm. The space between the alumina plate 404 and the negative electrode 402 and the space between the alumina plate 405 and the positive electrode 403 are set at 0.5 mm respectively.
[0073] The exhaust gas flow rate flowing in the plasma generator 304 is set at 8.5 L/min, and the exhaust gas temperature is adjusted at 214° C. by a heater (not shown). The discharge waveform shown in FIG. 1 is set at the burst waveform having the basic waveform of 3000 Hz. Two kinds of voltage values of 6.6 kVp-p and 7.0 kVp-p are used as the basic waveform voltage.
EXAMPLE 1
[0074] The basic waveform is set at a 6.6-kVp-P sine wave
[0075] Hz), the basic waveform iteration count is set at twice, and the burst period is set at 300 Hz. In this case, the electric power consumption is 4.7 W. In the above conditions, the burst period has the length equal to the ten periods of the basic waveform. Therefore, the undischarged periods of eight basic discharge waveforms 8 remain after the discharge period during which the basic waveform is repeated twice.
EXAMPLE 2
[0076] The basic waveform is set at a 7.0-kVp-P sine wave
[0077] Hz), the basic waveform iteration count is set at once, and the burst period is set at 300 Hz. In this case, the electric power consumption is 4.5 W.
EXAMPLE 3
[0078] The basic waveform is set at the 7.0-kVp-P sine wave (3000 Hz), the basic waveform iteration count is set at twice, and the burst period is set at 300 Hz. In this case, the electric power consumption is 5.3 W.
EXAMPLE 4
[0079] The basic waveform is set at the 7.0-kVp-P sine wave (3000 Hz), the basic waveform iteration count is set at three times, and the burst period is set at 300 Hz. In this case, the electric power consumption is 8.7 W.
EXAMPLE 5
[0080] The basic waveform is set at the 7.0-kVp-P sine wave (3000 Hz), the basic waveform iteration count is set at twice, and the burst period is set at 150 Hz. In this case, the electric power consumption is 2.6 W.
EXAMPLE 6
[0081] The basic waveform is set at the 7.0-kVp-P sine wave (3000 Hz), the basic waveform iteration count is set at twice, and the burst period is set at 600 Hz. In this case, the electric power consumption is 10.6 W.
COMPARATIVE EXAMPLE
[0082] The continuous waveform discharge is performed by continuously applying a 6.6-kVp-P sine wave (300 Hz). In this case, the electric power consumption is 5.8 W. Table 1 shows the summary of the conditions, the electric power consumption, and the PM purification ratio of Examples and Comparative Example.
TABLE 1 Comparative Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example Basic 6.6 7.0 7.0 7.0 7.0 7.0 6.6 waveform voltage (kVp-p) Basic 3000 Hz 3000 Hz 3000 Hz 3000 Hz 3000 Hz 3000 Hz 300 Hz waveform frequency Basic twice one twice Three twice twice (continuous) waveform times iteration count Burst period 300 Hz 300 Hz 300 Hz 300 Hz 150 Hz 600 Hz (continuous) Electric 4.7 W 4.5 W 5.3 W 8.7 W 2.6 W 10.6 W 5.8 W power consumption PM about about about about about about about purification 75% 83% 88% 92% 67% 86% 50% ratio
[0083] FIG. 6 shows relationship between the PM purification ratio and electric power consumption in Examples 1 to 4 and Comparative Example. FIG. 7 is a data plot showing a relationship between the burst period and the PM purification ratio in Examples 3, 5, and 6. The PM purification ratio is a ratio (in terms of weight) of PM which is decreased by causing the exhaust gas to pass through the plasma generator 407 . Assuming that the amount of PM included in the exhaust gas is set at a pre-plasma process PM amount before the exhaust gas passes through the plasma generator 407 while the amount of PM included in the exhaust gas is set at a post-plasma process PM amount after the exhaust gas passes through the plasma generator 407 , the PM purification ratio is computed by PM purification ratio=100×((pre-plasma process PM amount−post-plasma process PM amount)/pre-plasma process PM amount).
[0084] Referring to FIG. 6 , the PM purification ratio is about 75% in Example 1 while the PM purification ratio is about 50% in Comparative Example, and the electric power consumption is 4.7 W in Example 1 while the electric power consumption is 5.8 W. That is, although Example 1 has the low electric power consumption compared with Comparative Example, Example 1 can obtain the higher PM purification ratio.
[0085] The difference is attributed to the fact that the intermittent discharge, in which the 3000-Hz basic waveform is repeated twice and then the eight undischarged periods remain, is performed in Example 1 while the 300-Hz basic waveform is continuously oscillated in Comparative Example. It is seen from the above fact that the PM purification can efficiently be performed when the basic waveform frequency is increased to set the undischarged period. In the electric power consuming method, the high-density discharge is performed by combining the basic waveform having the high discharge energy and the undischarged period rather than the electric power is consumed by the continuous basic waveform having the low discharge energy, which allows the efficiency to be increased in the PM purification. That is, the PM purification efficiency can be increased by instantaneously applying the high energy rather than evenly applying the energy.
[0086] When compared with Comparative Example, the PM purification ratio is increased although the electric power consumption is small in Example 1. This means that the PM purification ratio of the intermittent discharge is higher than that of the continuous discharge under the same conditions.
[0087] The PM purification ratio is about 83% in Example 2 while the PM purification ratio is about50% in Comparative Example, and the electric power consumption is 4.5 W in Example 1 while the electric power consumption is 5.8 W.
[0088] Compared with the difference between Examples 1 and 2, not only the electric power consumption is smaller but also the PM purification ratio is larger in Example 2. Example 1 differs from Example 2 in that the basic waveform voltage is 7.0 kVp-p (6.6 kVp-p in Example 1) while the basic waveform iteration count is once in Example 2 (twice in Example 1). That is, in Example 2, the basic waveform voltage is increased by 6% compared with Example 1, and the basic waveform iteration count is decremented from twice to once.
[0089] Examples 1 and 2 have the same burst period of 300 Hz. However, in Example 2, the PM purification ratio can be increased while the basic waveform iteration count is decremented. This is attributed to the effect that basic waveform voltage is increased by 6%.
[0090] Consequently, it can be concluded that increasing the basic waveform voltage to simultaneously decrease the basic waveform iteration count is effective method of enhancing the PM purification ratio without increasing the electric power consumption under the condition in which the exhaust gas flow rate is kept constant. That is, the PM purification ratio and the low electric power consumption can be pursued by adjusting the basic waveform amplitude and the basic waveform iteration count.
[0091] Then, Examples 2 to 4 will be compared to one another. Examples 2 to 4 differ from one another in the condition of the basic waveform iteration count. As can be seen from FIG. 6 , the PM purification ratio is increased as the basic waveform iteration count is incremented. However, an increase rate of the electric power consumption is larger than an increase rate of the PM purification ratio.
[0092] Then, Examples 3, 5, and 6 will be compared to one another. Examples 3, 5, and 6 differ from one another in the burst period. The burst period is ( 1/300) second (300 Hz) in Example 3, the burst period is ( 1/150) second (150 Hz) in Comparative Example 5, and the burst period is ( 1/600) second (600 Hz) in Comparative Example 6.
[0093] As can be seen from FIG. 7 , the PM purification ratio is decreased when the burst period is shortened to some extent (when time is lengthened in the case where the burst period is expressed by time). As can be seen from the comparison of the Example 3 with Example 6, the burst period has the optimum range in the case where the PM purification ratio and the low electric power consumption are pursued. That is, the number of discharge periods (determined by the basic waveform, the basic waveform period, and the basic waveform iteration count) is determined by setting the burst period. On the other hand, in the case where the actual exhaust gas flow rate is excessive for the exhaust gas flow rate which can be processed during one discharge period, several discharge periods to be generated are required during the exhaust gas passes through the reactor. For example, the desired number of discharge periods is computed based on (actual exhaust gas flow rate/exhaust gas flow rate which can be processed during one discharge period). Accordingly, the burst period is adjusted according to the flow rate of the exhaust gas entering the reactor, so that the optimum number of discharge periods can be set according to the exhaust gas flow rate, and the PM purification ratio and the low electric power consumption can be pursued.
[0094] As can be seen from the above demonstration data, in the intermittent discharge mode in which the discharge and the no-yet discharged are alternately repeated, by adjusting the basic discharge waveform voltage, the basic discharge waveform iteration count, and the burst period, the purification efficiency in the plasma reaction can be enhance while the electric power consumption is suppressed.
[0095] The invention can be applied to the purification of the exhaust gas discharged from the automobile lean burn engine, the purification of the smoke exhaust discharged from the internal combustion engine installed in the shipping, and the purification of the smoke exhaust discharged from the internal combustion engine of the power generator or the like. | In an exhaust gas purifying technique in which discharge is utilized, the invention provides a technique in which purification efficiency can be enhanced while an increase in electric power consumption is suppressed. A discharge mode including a discharge period and an undischarged period is adopted in a configuration in which a plasma process is performed to exhaust gas from a Diesel engine by generating the discharge in a plasma generator. A basic waveform periodically exists in a repeated manner in the discharge period, and the discharge is not performed in the undischarged period. An amplitude and/or a period of the basic waveform is controlled according to a load on the Diesel engine, a continuous iteration count of the basic waveform is controlled according to purification reaction efficiency in the plasma process, and the burst period is controlled according to an exhaust gas flow rate. | 5 |
BACKGROUND OF THE INVENTION
This invention is in the field of mechanical devices, and relates to filters for reducing pollution from conventional wood-burning fireplaces.
A number of communities have adopted ordinances which are intended to limit the amount of smoke or other pollutants emitted by wood-burning fireplaces. Such ordinances are especially common in ski resort areas and other communities in mountainous areas which have abundant supplies of wood nearby, and in which deliveries of natural gas or fuel oil would be especially expensive, and in various regions where large populations, automobiles, and other factors combine to pose chronic air pollution problems.
However, since it is difficult to limit the amount of smoke emitted by a residential fireplace once it has been built, most such ordinances take the form of zoning-type controls that limit the number of fireplaces which can be built in new developments, and do not make any effort to reduce the amount of smoke emitted by existing fireplaces.
For a number of reasons, a better approach would be to reduce the amount of smoke, dust, and other pollutants emitted by the fireplaces, during use.
Various types of filters have been proposed for the flue channels (this term includes brick chimneys, metallic exhaust pipes, or other fireplace exhaust outlets) of certain types of fireplace assemblies. However, to the best of the Applicants knowledge after a diligent search of the prior art, the only such filters that have been proposed to date are designed as components of large, complex assemblies which comprise complete fireplaces. Examples include the filter assemblies shown in the fireplaces described in U.S. Pat. Nos. 4,279,239 (Blum 1981) and 4,557,687 (Schirneker 1985). Both of these proposed types of filters are contained within large hood-type assemblies that appear to extend from the top of a fireplace opening, all the way up to roughly the height of a ceiling; therefore, these filters cannot be retrofitted into existing fireplaces. In addition, it appears that none of those proposed systems have actually been manufactured and are available for purchase by the public.
Various filters and catalytic converters are used with enclosed wood-burning stoves, and factory smokestacks; examples are described in U.S. Pat. Nos. 4,286,528 (Willard 1981), 4,470,834 (Fasanaro et al, 1984), and 3,706,182 (Sargent 1972). However, as used herein, the term "fireplace" does not include wood-burning stoves which provide a complete enclosure for burning wood, or to incinerators, factory smokestacks, or other such burning chambers. Instead, as used herein, the term "fireplace" is limited to conventional open-hearth fireplaces that are enclosed in front only by mesh-type screens or glass doors, as commonly used in single-family residences, primarily for burning wood (although other fuels such as petroleum-based starter logs, rolled-up newspapers, etc. are often used), and which radiate heat into a room directly from flames that are visible from outside the fireplace.
Although it might appear to be obvious to provide smoke-and-dust filters in the flues of conventional fireplaces, not a single such unit is commercially available, and discussions with several fireplace manufacturers' representatives have indicated several reasons why such units are not being manufactured and sold.
The most important factor involves a fear that if a filter element becomes clogged or otherwise blocked, even if only partially blocked, then air flow out the flue channel will be impeded, and the smoke and hot exhaust gases will exit the front opening and go directly into the room, causing major annoyance and a possible fire hazard. This fear is greatly aggravated by the fact that the hot gases that rise from burning wood contain unburned organic molecules that can condense on any surface that is cooler than the hot exhaust gas, thereby forming creosote, a sticky residue that both (1) greatly increases the danger of clogging a fireplace filter, and (2) poses a fire hazard in its own right, since creosote if flammable if heated sufficiently. Furthermore, if a fireplace filter does become clogged, and smoke begins pouring out of the front opening of the fireplace into the room, the intense heat generated by the fire would make it extremely difficult to reach and manipulate the filter, to replace or remove the filter element.
Another relevant factor concerns air flow and heat conduction in fireplaces. Glass fireplace doors are designed so that they will not be air-tight; they are designed to allow a certain amount of air to pass through the cracks between the doors, to help keep the glass in the doors from becoming overheated. If a filter were to impede the flow of hot exhaust gases out of the flue channel, these glass doors might be jeopardized and might be heated to the point of breaking or warping.
The subject invention discloses a device and method for resolving and overcoming those concerns, and provides a fireplace filter that can operate in a safe and effective manner. It is particularly suited for use in ski resort towns and other areas that restrict or prohibit the installation of new fireplaces.
Accordingly, one object of this invention is to provide a filter-and-fan assembly which can be installed into new fireplaces or retrofitted into existing fireplaces, for filtering dust and smoke (and possibly other agents, such as creosote-generating organic compounds) out of the hot exhaust gases that are created when wood is burned in fireplaces, without creating a major risk of clogging that would create a smoke or fire hazard.
Another object of this invention is to provide a convenient, practical, and relatively inexpensive means for reducing the amount of smoke that is emitted by residential fireplaces in communities that have high numbers of such fireplaces.
These and other objects of the invention will become clear through the following description and drawings.
SUMMARY OF THE INVENTION
This invention discloses a filter-and-fan assembly that can be installed into new fireplaces or retrofitted into existing fireplaces, for filtering dust and smoke out of the hot exhaust gases that are created when wood is burned in fireplaces. This filter assembly is provided with a mechanism that can move the filter out of the flue channel (i.e., the chimney or other exhaust outlet) if the filter becomes clogged by creosote and/or smoke particles. If desired, the mechanism that moves the filter out of the flue path can be automated under the control of a monitoring device, such as an electronic smoke detector mounted in front of the fireplace above the fireplace opening. Alternately, a long, thin filter element can be continuously scrolled through a flue channel. These means for avoiding blockage or hindrance of the flue channel can overcome a major obstacle that, until now, has completely blocked the development and adoption of smoke filters for conventional open-hearth fireplaces.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view showing a smoke filter and fan blade positioned in the flue channel of a fireplace, and an ejector motor controlled by a smoke detector mounted above the fireplace opening.
FIG. 2 depicts an access door panel and spacer bracket, which can be coupled to a filter.
FIG. 3 is a cutaway side view showing a filter element that can be inserted into a support bracket through the front opening of a fireplace, to eliminate the need for a special access door for the filter, and which is mounted in a hinged support bracket held in place by a latch that can be easily disengaged if a fire is going.
FIG. 4 is a cutaway side view showing a relatively thin paper-type filter element mounted in a scrolling device, allowing the filter to be continuously pulled through the smoke-gathering zone.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings more particularly by reference numbers, number 10 in FIG. 1 refers to an open-hearth fireplace which is enclosed on all sides except the front by a hearth floor 12, a back wall 14, a firebox ceiling 16, and side walls 18, all of which are made of or covered by highly fire-resistant materials such as suitable types of concrete or brick. Front opening 20 is flanked above and below by support tracks 22 and 24, which allow a metallic mesh screen and glass doors (not shown) to be opened or closed. A decorative facade 26 made of brick, stone, metal, glass, or other fire-resistant material is located above the front opening 20. A log stand 28 is used to support logs 30.
If the fireplace is positioned against an external wall, the fire-resistant back wall 14 may be covered by an exterior layer of siding, brick, or wood 32; alternately, if the fireplace and chimney are made of brick or other suitable material, the fire-resistant back wall 14 may directly provide the exposed exterior surface. In addition, a filter system as described herein can also be used in fireplaces that are positioned away from any walls and designed to emit heat into a room from all sides, or in fireplaces that are built into internal walls and designed to heat two different rooms. Fireplace 10 may comprise a partially pre-fabricated unit which is purchased as a subassembly and then installed into a house or room; alternately, the hearth, walls, and other necessary components can be constructed entirely by bricklayers or carpenters. All of the foregoing components and options are conventional and are widely known and used in the prior art, and they may be modified in various ways as known to those skilled in the art.
The flue channel 40 may be formed by a brick chimney, a metallic pipe or duct, or any other suitable outlet for hot exhaust gases emitted by a fire in the fireplace. Positioned within flue channel 40 is a filter 50, which comprises a porous filter element 52 surrounded around its periphery by a frame 54 as shown in FIG. 2. When in use during a fire, filter 50 is supported and held in place in the fireplace flue channel 40 by a filter support bracket 42. The support bracket 42 is permanently affixed inside the flue channel 40, and remains stationary while new filters are inserted and removed whenever necessary. Access to the support bracket 42 is provided by means of access channel 44, which opens in the front of the fireplace. Before a fire is started in the fireplace, a clean filter 50 is inserted into support bracket 42 via access channel 44. This positions the filter 50 directly in the path of the hot exhaust gases that are exiting the fireplace through flue channel 40.
The front opening of access channel 44 is normally covered and closed by a door panel 60, which has a handle 62 or other suitable means for gripping and opening the door panel 60. In one preferred embodiment, shown in FIG. 2, the back side of door panel 60 is coupled directly to a spacer bracket 64. In an alternate embodiment, the door panel 60 can be purely decorative, and can be secured to the fireplace front by any suitable means, such as hinges along the top or bottom or resilient spring-type clip fittings, while the spacer bracket 64 can be independent.
The spacer bracket 64 has a distal end 66 fitted with coupling means that can be coupled to filter 50. This filter coupling can comprise any suitable mechanism that will sustain sufficient tension to allow a filter to be pulled out after use. For example, metal pins 68 on spacer bracket 64 can be inserted into accommodating slots, eyelets, or lugs 56 on the side of filter frame 54.
The spacer bracket 64 allows the filter 50 to be pushed all the way into the support bracket 42. When in use, the filter 50 will filter out and remove smoke and dust particles and creosote components from the hot exhaust gases that rise from the fire, thereby reducing the amount of air pollution emitted by the fireplace.
After a fire has died or cooled off to the point where it is no longer emitting any substantial smoke, filter element 50 (which is now considered "dirty" or "used") is removed from the flue channel 40 by pulling out the access door panel 60. If the filter 50 has been properly coupled to the spacer bracket 64, then the filter element will also be pulled out as the access door panel 60 and support bracket 64 are pulled out of the access channel 44. The used/dirty filter 50 is uncoupled from the spacer bracket 64 and replaced by a clean filter, to prepare for the next fire.
As shown in FIG. 1, a fan blade 80 is positioned above filter 50, to draw smoke and exhaust gases up through the filter and to prevent the buildup of pressure in the burning zone, beneath the filter. The fan blade 80 is mounted on a rotating axle 82 which is supported by an open-framed mounting bracket that does not significantly impede the flow of exhaust gases up through the flue channel.
Axle 82 can be coupled directly to an electric motor if desired, if the motor is properly designed and provided with adequate protection against hot exhaust gases, smoke, and creosote. Alternately, axle 82 can be fitted with a sprocket or gear that can be driven by a chain or belt 84 (or other suitable mechanical means) as shown in FIG. 1. This allows a less expensive electric fan motor 86 to be placed in a sheltered location that is not located in the path of flue channel 40. This arrangement can minimize exposure of the fan motor 86 to smoke, creosote, and hot exhaust gases, which might foul the motor or require a substantially more expensive design. The fan motor can receive electric power through a standard electrical cord 88 that passes through a side wall (if desired) and is wired or plugged into an electrical power outlet 89. A power switch should be provided somewhere in the circuit that is easily accessible, to allow users to turn the fan motor 86 on and off at will.
One of the important features of this invention is a means for easily removing filter 50 from the path of flue channel 40, in case the filter becomes clogged or dirty to a point where flow through the filter is impeded and smoke begins exiting the fireplace out of the front opening, in an undesirable and potentially dangerous path. This can be done by mounting a smoke detector 100 in front of the fireplace, either directly on or above the front facade 26 (as shown in FIG. 1) or at any other suitable location, such as attached to a mounting bracket hanging from a ceiling location directly above or near the fireplace front.
In a manual method of ejecting a clogged or dirty filter, the smoke detector 100 will sound an alarm if smoke begins exiting the fireplace through the front opening. If that happens, anyone who is at home can simply pull out the filter, manually, by removing the access door panel 60 and then pulling out the spacer bracket 64 and the filter 50. This method can be reliable in the vast majority of cases, since someone should be at home whenever a fire is going in a fireplace while the glass doors are open. If the users need to leave the house for any reason while a fire is still burning, they can simply pull out the filter before they leave, leaving the flue channel open.
Alternately, an automated system for ejecting a filter can be provided if desired, as shown in FIG. 1. In this approach, a filter ejector motor 90 is positioned in a sheltered location, hidden behind the front facade 26 but outside of the flue channel 40, near spacer bracket 64. The axle of this motor 90 is fitted with a rubberized pinch roller, a pinion gear or sprocket, or any other suitable drive mechanism which can interact with a rail, gear rack, chain, or other accommodating device that is mounted on or coupled to the spacer bracket 64 (for example, a gear rack 92 is shown mounted on the side of spacer bracket 64 in FIG. 2, for use with a rack-and-pinion drive system). If the smoke detector goes off, indicating that the filter 50 has become too clogged or dirty to allow proper exhaust flow, then an electronic signal generated by the smoke detector 100 will close a switch 94, thereby activating the filter ejector motor 90. The filter ejector motor will drive the filter out of the flue channel, thereby allowing free flow of exhaust gases up the chimney. If desired, the spacer bracket can be equipped with a cutoff switch, to open the electric circuit and turn off the ejector motor 90 after the filter has been pulled out of the flue channel 40. The filter can be ejected partway through the access door, which will render it visible to anyone in the room, or it can be moved into an alternate holding position inside the fireplace assembly.
This system can also be used to provide a chimney damper, to completely close off the flue channel whenever the fireplace is not in use. This is done by simply inserting a solid plate into the flue channel, in place of a filter, until the plate settles into support bracket 42 (when used for this purpose, item 42 in FIG. 1 will serve as a damper support bracket, and item 50 will be a solid damper plate rather than a porous filter element). This provides an easy, clean, and convenient way of opening and closing the damper, which can be done by anyone standing in front of the fireplace, and it eliminates the need for getting down on the knees, buttocks, or backside and then having to reach up inside a dark, dirty, sooty fireplace whenever the damper needs to be opened or closed.
Various other means can be used, if desired, to emplace a smoke filter in a fireplace flue in a manner that will allow the filter to be ejected or otherwise removed from the flue channel, while a fire is still burning, if the filter becomes too clogged or dirty to allow proper air flow through it. For example, as shown in FIG. 3, a filter element can be secured inside a support bracket 120 which rotates around a spring-loaded hinge 122 mounted on the ceiling of the firebox near the mouth of the flue channel 130. For use, the support bracket and filter element can be rotated and swung up into position until the front edge of the support bracket 120 engages a spring-loaded latching mechanism 124 mounted in front of the flue channel 130. The latching mechanism 124 can be disengaged (thereby allowing the spring-loaded support bracket and filter to swing out of the way of the flue channel) either automatically (by means of a motor-operated or solenoid-operated latch actuator), or manually. Manual activation can utilize, for example, a small cable or chain coupled to a handle mounted in any location that is accessible by hand (such as on the front of the fireplace) or positioned inside the firebox and accessible to manipulation by a poker, tongs, or other log-handling device that can be inserted into the firebox while a fire is burning, to pull the handle.
It should be noted that FIG. 3 depicts means for emplacing a filter element in flue channel 130, and for removing the filter from the flue channel in case the filter element becomes clogged, which does not require a special access door mounted on the front of the fireplace. Instead of a special access door, the normal fireplace opening 132 can be used to access the filter element.
SCROLLING FILTER DEVICES
In another alternate preferred embodiment in a fireplace assembly 200, shown in FIG. 4, a long segment of a relatively thin filter element 210, made of a suitable heat-resistant material comparable to filter paper, is mounted on or in a supply device 212, such as supply reel 212. The filter element 210 passes across the throat of the fireplace flue 202, constrained so that it remains located in a preferred track or position by tension or other suitable mechanical means, and is collected on a take-up reel 214. When in use while a fire is burning, the same motor 220 which drives the fan 204 also works, through a gear reducer 222, to slowly rotate the take-up reel 214. This causes the take-up reel 214 to slowly pull the filter element 210 through the soot-gathering zone in the throat of the fireplace flue 202, so that any particular portion of the filter element 210 will remain in the soot-gathering zone for only a limited period of time. This type of continuous scrolling method and device will continuously pull fresh filter paper into the soot-gathering zone, and will prevent the filter from becoming clogged.
The "dwell time" (i.e., the amount of time that a particular point on a filter element should remain within the soot-gathering zone in the throat of a fireplace flue) will depend on various factors, including the thickness and pore size of the filter paper being used, and in some cases the nature of the wood being burned. Accordingly, the preferred "dwell time" can be optimized based on routine experimentation for any selected type of thin filter elements, and can be controlled by varying the speed of rotation of the takeup reel. In general, is it anticipated that preferred dwell times for most types of filter paper are likely to be in the range of about 2 minutes to about 10 minutes. If desired, variation in takeup speed can be provided manually, by giving a homeowner several speed settings through a switch or knob (this will also allow a homeowner to accommodate the fact that takeup speed will vary as the takeup reel accumulates more filter paper), or automatically, through a relatively simple control circuit.
The positions of the supply and takeup reels shown in FIG. 4 (i.e., with the supply reel behind the flue, and the takeup reel in front of the flue) can be used in a fireplace assembly that extends out from a wall and is provided with a side access panel or other suitable means of access to the reels, so that both reels can be removed and replaced when necessary. In an alternate preferred embodiment, the two reels can be placed on the left and right sides of the flue, so that both reels can be reached and replaced through the front access door 208 or possibly the main front opening of the fireplace.
In another alternate preferred embodiment, the rotating supply reel 212 can be replaced by a device which holds folded and pleated filter paper, comparable to a paper towel dispenser that dispenses pleated paper towels. Regardless of what type of supply device is used, the "tail end" of the filter paper should not be securely attached to it; instead, the tail end should be released so that it can be pulled completely through the flue channel, so that it cannot become clogged when the end of the reel or other supply is reached.
If desired, a continuously scrolling unit as shown in FIG. 4 can be provided with a suitable mechanism (either automated or manual) for intervening in case a malfunction occurs, as evidenced by a substantial quantity of smoke emerging from the front of the fireplace and triggering a smoke detector 206 mounted above the front opening of the fireplace. Suitable intervention could utilize any of several types of mechanisms, such as a manual or automated cutting device (comparable to the small cutting devices used on many telephone fax machines) to cut the filter element at a suitable location, such as location 230, so that it will be pulled out of the flue path by the takeup reel 214. Alternately or additionally, the takeup reel can be provided with a manual crank, accessible through the front door panel 208.
Accordingly, the scrollable filter device described herein, and its various alternate embodiments, can be described as comprising (1) a long segment of thin filter element which is designed and suitable for filtering particulates out of hot exhaust gases that pass through the flue channel when a fire is burning in the fireplace, (2) a supply device which initially contains the segment of filter element, and which is designed to allow the filter element to be pulled through the flue channel, thereby gradually removing the filter element from the supply device, and (3) a takeup device which continuously operates when a fire is burning in the fireplace, to pull the filter element through the flue channel and then out of the flue channel at a speed which prevents any portion of the filter element from becoming clogged to an extent which prevents hot exhaust gases from passing through the flue channel.
GENERAL OPERATION
It is anticipated that a fireplace owner will keep several filters, so that a clean filter will be conveniently available at all times. The porous filter elements described herein can be made of any suitable material that can withstand high temperatures, such as ceramic whiskers, metallic fibers, etc. Such materials are commercially available, and are discussed in various patents and other references such as U.S. Pat. 4,673,658 (Gadkaree et al, 1987) and other patents cited therein. Such filters can be disposable filters, comparable to disposable furnace filters, which can be replaced before each new fire. However, since filters that can withstand very high temperatures will probably be significantly more expensive than, for example, cheap furnace filters, it is anticipated that reusable filters may also be used, and regenerated after each use, by heating them to vaporize and remove creosote components and then spraying them with water to remove dust and particulates), or by soaking or washing them with suitable detergents or solvents that can remove creosote as well as smoke particles. Regeneration of used filters can also be carried out by service companies that specialize in such operations, comparable to dry cleaners.
It is also anticipated that in communities in which new fireplaces are not allowed because of air pollution reasons, transferable rights might be created, in which a homeowner can obtain permission from the local government to build a new fireplace, if he or she will provide it with a filter and also pay to have filter units retrofitted into one or more existing fireplaces, so that no net increase in smoke emissions will be caused by the new fireplace.
Finally, it should also be noted that the filtering devices of this invention can substantially decrease both (1) the need for periodic maintenance and cleaning of fireplace chimneys, and (2) the risk of fires caused by creosote buildup in chimneys that have not been properly cleaned.
Thus, there has been shown and described a new and useful device and method for using fireplace filters to reduce smoke, dust, and other pollutant emissions from fireplaces, in a manner that is safe and convenient and overcomes the danger of clogged filters leading to smoky rooms and fire hazards. Although this invention has been exemplified for purposes of illustration and description by reference to certain specific embodiments, it will be apparent to those skilled in the art that various modifications, alterations, and equivalents of the illustrated examples are possible. Any such changes which derive directly from the teachings herein, and which do not depart from the spirit and scope of the invention, are deemed to be covered by this invention. | This invention discloses a filter-and-fan assembly that can be installed into new fireplaces or retrofitted into existing fireplaces, for filtering dust and smoke out of the hot exhaust gases that are created when wood is burned in fireplaces. This filter assembly is provided with a mechanism that can move the filter out of the flue channel (i.e., the chimney or other exhaust outlet) if the filter becomes clogged by creosote and/or smoke particles. If desired, the mechanism that moves the filter out of the flue path can be automated under the control of a device such as an electronic smoke detector mounted in front of the fireplace, above the fireplace opening. Alternately, a thin filter-paper type of filtering element can be continuously scrolled through the flue channel. A rotating fan blade can be provided directly above the filter element, to ensure that exhaust gases are actively drawn up through the filter. These means for avoiding blockage or hindrance of the flue channel can overcome a major obstacle that, until now, has completely blocked the development and adoption of smoke filters for conventional open-hearth fireplaces. This invention also discloses a convenient and clean method of opening and closing a fireplace damper without having to reach into a sooty fireplace, by inserting a solid damper plate (rather than a filter element) into a filter support bracket in a flue channel. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to sun visors for vehicles, and more particularly, to a sun visor having a molded plastic core member.
It is well known to provide a sun visor for the windshield of a vehicle, e.g., an automobile for shielding the eyes of the driver and front seat passenger from harsh direct or glaring light, primarily sunlight. Conventional sun visors have been constructed with a solid inner core board of a pressed wood material, and an outer cloth covering of foam-backed cloth that is sewn along a seam circumjacent the periphery of the core board. If it is desired to provide components such as a mirror, electrical circuitry for lighting the mirror, and an extender for increasing the coverage of the sun visor, it has been necessary to mount these components onto a side of the inner core board. The addition of these components tends to increase the thickness of the sun visor. In addition, a separate assembly operation is required to mount each component onto the core board, resulting in an accumulation of tolerances of the components as well as an accumulated variation introduced by each assembly operation.
In recent years, visor assemblies have been constructed with molded plastic core members. Typically, these are molded of a plastic material in two half sections or clam shells joined together by a hinge. The half sections form a cavity or recess within the core, into which the internal components such as the lighting circuitry including lamps and mirror are all located. The core halves are then pressed together and bonded by a heat sealing operation or the like.
In U.S. Pat. No. 5,054,839, issued to White, et al., a plastic core sun visor is disclosed in which the core members 12 and 14 are each covered with an upholstery material 16 and are then locked together by the engagement of rigid pins 44 extending inwardly adjacent the perimeter of one of the core members in snap-in engagement. A disadvantage with this design is that once the relatively expensive core mold has been built, there is no flexibility for changes in the overall size of the sun visor which are often required to accommodate varying sun visor size requirements in newly designed vehicles. Thus, if the size of an existing plastic core sun visor size is either too large or too small, a new mold must be made to change the size of the sun visor. It is desired to provide an improved sun visor that overcomes the above disadvantages.
SUMMARY OF THE INVENTION
The present invention provides a sun visor assembly having an integrally molded core member including molded access compartments for receiving various visor components therein. A cover member having a foundation base is folded over the core member and is attached to itself along a seam. The cover member may be selectively modified to a variety of desired shapes and sizes without requiring modification of the core member.
In particular, the invention provides, in one form thereof, a sun visor having a molded plastic core member wherein a first face of the core member includes an integrally molded extender assembly including channel members for slidingly receiving an extender blade therein, wherein the extender is slidable between a retracted position and an extended position. A second face of the core member includes a series of integrally molded channels and grooves which are formed in the mirror platform for the reception of a series of wires comprising the lighting circuitry. An upholstery covering member is folded over the core member and secured along a seam. The covering member includes a pair of access openings through which a mirror frame, mirror, door, lens, and spring assembly (mirror and door assembly) is attached to the core member. The mirror and door assembly is removable from the core member to permit access to the lighting circuitry for servicing.
An advantage of the sun visor assembly of the present invention is that the outer covering of the sun visor may be removed and replaced by a covering of a different size and shape to permit alteration of the geometry of the sun visor body without requiring a new inner core.
Another advantage of the sun visor assembly of the present invention is that the integral core design accommodates larger mirror and extender sizes.
Yet another advantage of the sun visor assembly of the present invention is that the sun visor has a less composite thickness than with prior designs which do not include the large radius structural beading around perimeter edges.
Still another advantage of the sun visor assembly of the present invention is that the lighted vanity mirror and wiring circuitry are serviceable.
A still further advantage of the sun visor of the present invention is that the integral core member eliminates the labor and parts necessary to attach the same components to a traditional core board.
The present invention, in one form thereof, comprises a sun visor assembly having a molded plastic core member and a outer covering material covering the core member. The covering material is substantially adhered to a foundation. The covering material is folded over the core member and fastened to itself in such a manner to secure the core member substantially within the covering material.
The invention further provides, in one form thereof, a method of assembly a vehicular sun visor wherein a molded plastic core member is provided and includes a groove molded in a first face. A conducting wire including a lamp is secured in the groove. The core member and the conducting wire are covered with a covering material having an access opening therein such that the access opening is aligned over the lamp. A mirror assembly is then removably mounted on the core member through the access opening. In addition, a door assembly is removably mounted to the mirror assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a sun visor assembly in accordance with the present invention;
FIG. 2 is an enlarged, assembled front elevational view of the sun visor assembly shown in FIG. 1;
FIG. 3 is an enlarged fragmentary sectional view of the sun visor assembly of FIG. 2, taken along line 3--3 in FIG. 2;
FIG. 4 is an enlarged sectional view of the sun visor assembly of FIG. 2, taken along line 4--4 in FIG. 2;
FIG. 5 is an enlarged front elevational view of the integral core member shown in FIG. 1;
FIG. 6 is an enlarged rear elevational view of the integral core member shown in FIG. 1, and additionally showing an extender blade attached thereto; and
FIG. 7 is an enlarged, fragmentary sectional view of the core member and extender blade taken along line 7--7 in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and in particular to FIGS. 1 and 2, there is shown a sun visor assembly 10 generally comprising a sun visor body 12 that is operably connected to a vehicle headliner (not shown) by means of a mounting bracket and arm assembly 14. Assembly 14 serves as a horizontal axis for rotation of the sun visor between a storage position and a first use position adjacent the front windshield.
Sun visor body 12 comprises a solid integral core 18 having a front face 19, a rear face 20 (FIG. 6), and an integral supplemental pin member 21 that is removably snap fit into a retainer 23. Upon disengagement of pin member 21 from retainer 23, assembly 14 also serves as a vertical axis for movement of the sun visor body to a second use position adjacent the side window. It is noted that for sun visors not requiring pin member 21, the front geometry may be adjusted by reorienting rod 66 relative to core 18 and adjusting the flex flap as required.
Body 12 further includes a single piece outer covering assembly 22 made of cloth 25 having a bonded foam backing 27, wherein cloth 25 is edge adhered to a kraft paper foundation 29. Covering 22 is folded over core 18 and is adhered (e.g. sewn or glued) substantially along its perimeter to form a double layered peripheral edge portion 24 (FIGS. 3,4) about periphery 26 of core 18. On one side of sun visor body 12, covering 22 is provided with an access opening 28 for receiving extender frame portion 32. Covering 22 is further provided with openings 30 for exposing a pair of lamps which shall be further described herein.
Core 18 comprises a single molded plastic piece, preferably made of ABS. Extender frame portion 32 of core 18 includes an opening 33 defined by end portions 34 and 36 for receiving an extender blade 38 therethrough. Extender blade 38 is a generally rectangular-shaped, molded plastic piece including a flat body portion 40 having a top edge 42, a bottom edge 44, a captured end 46, and a free end 48. Top edge 42 and bottom edge 44 are preferably in the form of beads to fit within the appropriate tracks in core 18. Extender blade 38 is further provided with a handle portion 50 having a decorative channel 52 therein. Handle 50 is raised from body portion 40 to facilitate grasping of the handle.
Core 18 is provided with an integral channel in rear face 20 to provide top 54 and bottom 56 tracks between which extender blade 38 is slidingly retained. Captured end 46 of extender blade 38 includes a pair of protrusions 58 which ride freely within corresponding tracks 54, 56. When blade 38 is fully extended, protrusions 58 catch on slots 60 (FIG. 7), thereby preventing blade 38 from becoming disengaged from tracks 54 and 56.
Referring now primarily to FIGS. 1, 2, and 5, front face 19 of core 18 includes a generally rectangular recessed portion 62 for receiving the lighting circuitry for the mirror and door assembly. As shown, mounting bracket and arm assembly 14 includes a generally L-shaped elbow 64 that is molded about a rod 66, which is tubular and receives a pair of power conductor wires 68 and 70 which are housed in wire harness 72 that is secured within a portion of top channel or groove 73 within core 18. Referring to FIG. 2, one end of each wire 68, 70 is connected to connector 74, which is connected to a source of electrical power in the vehicle. The other end of each wire 68, 70 is channeled through access groove 76 and then through groove 78 in recessed portion 62 and into main circuitry groove 80. In groove 80, wire 68 is connected to lamp housing 82, and wire 70 is connected to switch assembly 84, which is mounted in switch housing area 85 in recessed portion 62. Another wire 86 extends through channels 88 and 80 and to lamp housing 82. In addition, wires 90 and 92 are located within groove 80 to communicate between lamp housing 82 and lamp housing 94.
As described above, a feature of the present invention is that the lighting circuitry may be attached directly to core 18 through a unique set of grooves, thereby eliminating the need for a separate stamped circuit to be attached to the core. Referring again to FIG. 5, lamp housings 82 and 94 each include a respective opening (not shown) which receives a respective upstanding alignment post 98, 100. In addition, integral clip members 102, 104 are provided for securing respective lamp housings 82 and 94 and corresponding lamps 106, 108 into respective lamp openings 110, 112 in recessed portion 62.
As shown in FIGS. 1 and 2, a generally U-shaped detent clamp 114 is positioned about recessed portion 115 on core 18 and surrounds a portion of rod 66. Clamp 114 is retained on core 18 by rivets 116. Rod 66 has flats that cooperate with detent clamp 114 to hold/lift the visor in the park position.
In the assembly of sun visor 10, once bracket and arm assembly 24, the lighting circuitry, and detent clip 114 have been properly installed on core 18, covering 22 is attached to core 18 such that access openings 30 expose lighting frame portions 118 and 120 including attachment hooks 122 and 124. Cover 22 is then adhered to itself as described earlier. As best shown in FIG. 3, edge 125 becomes nested or trapped in place by lip 127 on core 18 when the perimeter of cover 22 is adhered together. This prevents the cover from sliding off the core. A mirror door and frame assembly 126 includes a frame 128 have a large central rectangular opening for receiving and exposing a mirror 130. Frame 128 is preferably molded from the same material as core 18. Frame 128 further includes two smaller end openings for receiving lenses 132 and 134 for placement over lamps 106 and 108, respectively. As best shown in FIG. 3, frame 128 further includes hooks 136 that engage hooks 122 and 124 in snap-on arrangement to removably secure frame 128 to core 18 through access openings 30 in cover 22. As frame 128 is snapped into place, opening 138 receives upstanding switch actuator 140.
As shown in FIG. 1, a rectangular portion of paper foundation 29 is missing from a portion of cover 22. As frame 128 is snapped into place, the urethane foam 27 of cover 22 is pressed into the various grooves in recessed portion 62 which essentially reduces wire vibration in the grooves.
After attaching mirror frame and door assembly 126 to core 18, a hinged cover or door 142 is removably connected to frame 128 by door springs 144, as shown in FIGS. 1 and 4. When door 142 is in its closed position, actuator pin 140 is depressed by the door thereby opening the electrical circuit. When door 142 is swung to its open position to expose mirror 130, pin 140 moves upwardly thereby closing the electrical circuit to energize lamps 106 and 108. It is noted that all wire channels as well as the extender channel become closed when the assembly operations are completed.
A feature of the present invention is that sun visor body 12 is easily serviceable. Frame 128 may be snapped off of core 18, thereby exposing lamps 106 and 108 as well as the wire circuitry through access openings 30 in cover 22. For example, if one of the wires in the circuitry is bad, the entire wiring harness can be replaced without destroying the visor. In addition, door 142 may be removed from frame 128 by removing hinge springs 144, which are preferably of a push/pull design. Springs 144 each includes a flat portion 145 that nests in a depression on the back of frame 128. Spring 144 is flexed in the direction of arrow 147, and door hinge pin 149 is then placed under the center of hook portion 151 of spring 144. The spring is then released which locks the parts together. Also, the mirror components, lamp housings, or lamps themselves may be serviced without requiring replacement of the visor. In addition, the extender may be disengaged from core 18 and replaced.
Another feature of the present invention is that cover 22 is folded over core 18 and is bonded along the perimeter. An advantage of this arrangement is that flex flap portion 146 of cover 22 is not part of plastic core 18. In addition, as best shown in FIG. 2, there is a relatively large spacing 148 between peripheral edge 26 of core 18 and the peripheral edge of cover 22. Both spacing 148 and the dimensions of flex flap 146 may be varied to change the size and dimensions of sun visor body 12 without requiring core 18 to be modified.
Another feature of the present invention is that cover 22 is removable from core 18 so that a visor of another shape and size can be mounted over the core. In addition, if desired, mounting bracket and arm assembly 14, including rod 66 may be removed from visor body 12, whereupon foundation 29 may be flexed sufficiently to permit edge 125 to extend over lip 127, thereby permitting cover 22 to be slidably removed from the core without damaging cover 22.
It will be appreciated that the foregoing is presented by way of illustration only, and not by way of any limitation, and that various alternatives and modifications may be made to the illustrated embodiment without departing from the spirit and scope of the invention. | A vehicular sun visor having a single molded plastic core member. A first face of the core member includes an integrally molded channel member for receiving an extender blade therein. The opposite face of the core member includes a series of integrally molded channels and grooves for the reception of a series of wires and lamps comprising the lighting circuitry. An upholstery cover member is folded over the core member and secured along a seam. The cover member is adhered to a rigid foundation and includes a pair of access openings therein through which a mirror and lens assembly is removably attached to the core member. The cover member defines the shape of the sun visor. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of methods and apparatus for the delivery of compressed gas for, inter alia, industrial or pipeline uses.
2. Description of the Prior Art
Nitrogen, air or other gas is used to service pipelines, tanks, or other items for the purpose of performing maintenance or some other operations. Typically dry air, nitrogen, or other gas is used, for example, to inert or dry pipelines 16 ( FIG. 1 ), or to propel pigs for cleaning or inspecting pipelines 16 . This dry air or nitrogen usually comes from either large motor or engine driven compressors 1 ( FIG. 1 ), from nitrogen gas generators 1 , which have a limited flow rate capability, or from liquid nitrogen which must be delivered to the site in sufficient quantities for the operation and then be pumped and vaporized with motor or engine driven pumps and heating equipment at the rate required by the application at hand. Nitrogen is the preferred gas to use for these applications due to its inherent nature of being relatively inert and very dry.
Time and cost are two major factors in determining what process to use in performing any of the operations. The fastest way to perform any of the operations is to obtain the highest flow rate of gas possible. In the current state of the art, this usually means using liquid nitrogen, which is the most expensive, equipment intensive and logistically difficult means.
The use of liquid nitrogen has been the preferred method of delivering gas for these applications because very high flow rates can be achieved at pressure required. When this method is used, the amount of gas must be estimated so that sufficient liquid nitrogen is available to complete the job. The disadvantages of this approach are the expense and logistics required for the supply and transportation of the liquid nitrogen, and the special equipment required to pump and vaporize the cryogenic medium.
The use of electric motor or engine driven compressors 1 to deliver the required gas (plus a nitrogen generator if necessary), although capable of delivering unlimited amounts of gas at a relatively low cost, is limited as to the rate at which the gas can be delivered and therefore increases the time required to perform the job.
Many of the operations that require a gas supply take place in hazardous locations (NEC Class 1 Division 2, or Zone 1 or 2) where the use of engines or electric motors 1 is discouraged, restricted, or require extensive safety provisions. In these cases both the use of the liquid nitrogen equipment and the compressors 1 present a potential problem that can usually only be remedied with expensive modifications to the equipment, or by using special equipment.
BRIEF SUMMARY OF THE INVENTION
The preferred embodiment of the invention is a method and apparatus for combining the advantages of the high flow rates that can be achieved using liquid nitrogen systems, with the lower cost and longer term operational capabilities of the compressors and nitrogen generators. The illustrated embodiment of the invention is a means for supplying high flow rates of gas by releasing the gas from one or more high pressure gas storage containers 10 (often known as “tube trailers” or “tube containers”). These gas storage containers 10 are arrays of high pressure cylinders that are interconnected with a manifold and are equipped with special valves that permit the high flow rates required by the operations. Multiples of these high pressure storage containers can be used for any single operation, with full containers replacing depleted containers 10 during the operation to maintain a sustained flow rate. Depleted containers 10 can be recharged by a nitrogen generator system 1 to achieve a longer operation and to meet the total volume requirement. The recharging can be performed off the hazardous site as discussed earlier.
An added benefit of this invention is that this procedure requires no power, in the form of gas or diesel engines or electric motors 1 , at the operation site. The absence of motors or engines 1 can be an advantage in hazardous areas and can increase the reliability of the delivery of the gas.
In addition, as compared to using liquid nitrogen, which typically must be delivered from a remote air separation plant, these banks of cylinders 10 can then be recharged with gas by portable compressors or nitrogen generators 1 .
Although the present invention still requires an estimate of the gas required, the cylinder banks 10 can be recharged with portable compressors and/or nitrogen generators 1 at or near the job site, albeit at a lower rate than is being delivered.
Considerably higher rates can be achieved with the present invention than with electric motor or engine driven compressors. The invention is normally operated with only low voltage control signals to control and record the flow of the gas, or can be operated with no power at all.
Thus the invention is defined as an apparatus for providing delivery of compressed gas to an application comprising at least one bank of compressed gas cylinders for storing gas at a pressure equal to or exceeding a predetermined delivery pressure; and a valve for controlling flow of gas from the bank to the application.
The apparatus further comprises a flowmeter coupled to the valve for monitoring flow of gas from the bank to the application. The flowmeter is preferably coupled to the valve downstream from the valve. The bank comprises a plurality of compressed gas cylinders coupled in parallel, coupled in series or as a cascaded system.
In another embodiment the apparatus further comprises a plurality of banks of gas cylinders. A corresponding plurality of valves are coupled to the plurality of banks of gas cylinders. A corresponding plurality of flowmeters are coupled to and downstream from the plurality of valves.
In still another embodiment the plurality of banks are divided into at least two sets of banks, each set having at least one bank of gas cylinders. At least one valve is coupled to each set of banks, a flowmeter is coupled to each valve, and at least two check valves are coupled to and downstream from the valves to permit selective detachment and coupling of each set of banks to the application.
The invention must also be understood to include the method of delivering compressed gas to an application or pipeline according the a method of operation using the above defined embodiments.
While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram which symbolically depicts a single bank of compressed gas cylinders coupled to a valve and flowmeter to deliver gas to an application or pipeline according to the invention.
FIG. 2 is a diagram of the invention wherein a plurality of banks of cylinders are employed.
FIG. 3 is a diagram of the invention of the embodiment of FIG. 2 where the plurality of banks employ a common flowmeter.
FIG. 4 is a diagram of the invention wherein a plurality of banks of cylinders are employed in at least two sets in which one set is used and then exhausted with the second set then coupled to the application or pipeline to take up the gas delivery after the first set of banks are depleted.
The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a diagrammatic depiction of a bank of high pressure cylinders 10 for storing the required gas at a pressure sufficiently higher than the required delivery pressure in the pipeline 16 or other application, so as to be able to maintain as high a flow rate as possible during delivery. Such a flow rate is substantially higher than that if the compressor/generator 1 were used to directly send gas to the pipeline 16 . The bank may be mounted on a transportable skid that can be loaded onto and off of a truck, barge, train car or aircraft. Alternatively, the bank can be integrally combined with the vehicle to provide a self-propelled unit. In general, while the delivery pressure can be understood to vary widely over the spectrum of all possible applications, for most pipeline deliveries a pressure in the range of approximately 100 to 500 psi is adequate. In addition the volume of gas which can be stored in a bank is highly variable according to the number and nature of gas cylinders ganged together to comprise the bank. Normally DOT cylinders would be used with maximum pressure capabilities of 2400 psig (3T-2400 tube) or 2850 psig (3T-2850 tube). The volume of each container depends on the length and number of tubes used. Other DOT and DOT exempt cylinders of various sizes may be used with pressures up to 5000 psig, arrayed into a bank of cylinders to make up a single container. However, container volumes in the range of 70,000 cubic feet to more than 185,000 cubic feet at 2400 psi or 2850 psi and at 70° F. are typical. The compressed gas is released from the bank of cylinders 10 through one or more valves 12 that serve to control the pressure and/or the flow rate of the delivered gas. A flow meter 14 may be included to monitor and/or record the flow rate and total flow of the delivered gas. The gas is delivered to the pipeline 16 or to another process or application.
The valve 12 may be incorporated as part of the bank of high pressure cylinders 10 or on a separate small skid with the flowmeter 14 . The flowmeter 14 is preferably located downstream of the valve 12 . The flowmeter 14 can be incorporated as part of the bank of high pressure cylinders 10 or on a separate small skid.
For higher flow rates, multiple banks of cylinders 10 a and 10 b may be used simultaneously delivering the gas in parallel as diagrammatically depicted in FIG. 2 . Two or more banks of high pressure cylinders 10 a , 10 b for storing the required gas at a pressure sufficiently higher than the required delivery pressure in the pipeline 16 so as to be able to maintain as high a flow rate as possible. The gas is released from the multiple banks of cylinders 10 a and 10 b through one or more valves 12 a and 12 b respectively that serve to control the pressure and/or the flow rate of the delivered gas. A flow meter 14 a and 14 b may be included to monitor and/or record the flow rate and total flow of the delivered gas through valves 12 a and 12 b respectively. The gas is delivered to the pipeline 16 or to another process or application. Valves 12 a and 12 b may be incorporated as part of each bank of high pressure cylinders 10 a and 10 b respectively or on a separate skid with flowmeters 14 a and 14 b respectively to control and measure the flow of gas from the multiple banks of cylinders 10 a and 10 b . The flowmeters 14 a and 14 b are preferably located downstream of the valves 12 a and 12 b . The flowmeters 14 a and 14 b can be incorporated as part of the bank of high pressure cylinders 10 a and 10 b respectively or a single flowmeter 14 can be used on a separate small skid to measure the combined flow of the multiple banks of cylinders 10 a and 10 b as shown diagrammatically in FIG. 3 . In the same way the function of valves 12 a and 12 b could be combined into a single valve to service banks 10 a and 10 b.
For long durations jobs, multiple banks 10 a to 10 n , where n is an arbitrary number, may be used sequentially, with one or more banks 10 a , 10 b , . . . delivering the gas while additional banks of cylinders . . . 10 n are standing by ready to deliver when the operating bank(s) 10 a , 10 b , . . . of cylinders become depleted of gas or the pressure gets too low to maintain the desired flow rate. The gas may be delivered through one or more check valves 18 a and 18 b located just before the delivery point into the process 16 so that the depleted bank(s) 10 a , 10 b , . . . may be removed from the process while the replacement bank(s) . . . 10 n continue the operation. The depleted banks of cylinders 10 a , 10 b , . . . can then be replaced with a fully charged bank of cylinders . . . 10 n . The depleted banks of cylinders 10 a , 10 b , . . . can then be removed or recharged as required for continued operation. A separate check valve 18 a , 18 b . . . may be provided for each bank 10 a , 10 b , . . . 10 n or check valve 18 a may be coupled via a manifold to a first set of banks 10 a , 10 b . . . which will be depleted first and then check valve 18 b may be coupled via a manifold to a second set of banks . . . 10 n which will be used next.
Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention.
Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations.
The words used in this specification to describe the invention and its various 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 in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
The definitions of the words or elements of the following claims are, therefore, defined in this specification 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 in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
Insubstantial 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 equivalently within the scope of the claims. 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.
The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention. | The invention is a method and apparatus for delivering large volumes of nitrogen gas, air, or other gas at high pressures from banks of high pressure cylinders and releasing that gas at the rate required by the operation. Not only can higher flow rates be achieved, but the absence of motors or engines can be an advantage in hazardous areas and can increase the reliability of the delivery of the gas. In addition, as compared to using liquid nitrogen, which typically must be delivered from a remote air separation plant, these banks of cylinders can then be recharged with gas by portable compressors or nitrogen generators. | 8 |
This is a continuation of application Ser. No. 953,409, filed Oct. 23, 1978.
FIELD OF THE INVENTION
The invention relates to cord guide, normally pulley, support means for the cords of a liftable shade, as a Roman shade or a venetian blind, and relates particularly to a type thereof having hanger means and cord guide housing means which are provided with a pivotal joint therebetween. The hanger means includes a ceiling or wall mountable bracket whereby the pulley and cords may normally occupy positions generally parallel with an adjacent wall but may during operation if desired be angled away from the wall without diminishing the ease or effectiveness of their operation.
BACKGROUND OF THE INVENTION
Liftable shades and the cord guide means, usually pulleys, used therewith have been known for a long time and during all of this period there has necessarily been some means present for supporting such pulleys in a predetermined position with respect to the shade. This has usually been a fixed position with respect to the shade and a position wherein the plane of the pulley was parallel to the plane of the window with which the shade was used. Since the normal method of handling the shade cords would involve maintaining them at least substantially in the plane of a given shade pulley, this would mean maintaining such cords at least substantially in a plane parallel to such window. A careful operator of the shade would have no difficulty in so doing but a careless operator of the shade cords might well stand at some distance from the window, or the wall adjacent the window, and would particularly do so if there were furniture adjacent the wall. In so doing, he would angle the cords at what sometimes became a substantial angle with respect to such wall. This often caused a cord feeding toward a pulley to fail to track with respect to such pulley and either go off the pulley entirely or at least jam between the edge of the pulley and the pulley support. This has in the past been met by providing various types of guiding devices in association with the pulley in order that the cord would be fed onto the pulley in proper alignment therewith regardless of the angle at which the majority of the cords were held with respect to the adjacent wall, i.e., with respect to the plane of the pulley. This has worked with a reasonable degree of satisfaction insofar as preventing the shade cord from escaping from the pulley but such guides normally generate a substantial amount of friction and thereby make more difficult the operation of the shade. While it is recognized that this is of no great consequence with small or short shades, in the case of large shades where there is already a substantial load present, the addition of such further frictional load is highly undesirable.
This problem has long been recognized but insofar as I am aware, there has been only one previous attempt made to deal differently with it. This attempt involved hanging the pulley from a horizontal pin, in somewhat of a loop and pintle arrangement, to permit the pulley to pivot around a horizontal axis parallel with the longitudinal extent of the shade. This permitted the pulley to angle away from the wall to follow the shade cords if same were so angled in somewhat the same manner as the blocks (pulleys) often used in various positions, as on the deck, of a sailboat. This has provided a substantially improved operation but because of the use of metal components and the permanence resulting from metal fabrication, it presents certain problems in manufacturing and inventorying which it is the purpose of the present invention to solve.
Accordingly, the objects of the present invention include:
1. To provide a support for a cord guiding means, usually a pulley means, usable in association with a liftable shade, as a Roman shade or a venetian blind wherein said cord guide support is made entirely from plastics material, wherein said cord guide support comprises a hanger section and a cord guide, usually pulley, housing section and wherein the said housing section will pivot with respect to the hanger section around an axis parallel with the longitudinal extent of the shade.
2. To provide a cord guide support, as aforesaid, which can be manufactured as an independent unit or which can by a simple modification be incorporated into a shade as an integral part thereof.
3. To provide a cord guide support, as aforesaid, in which the cord guide housing section and the hanger section comprise independent parts having broad mutually engageable load bearing surfaces rather than a pivot-and-pin relationship.
4. To provide a cord guide support, as aforesaid, in which the housing section has a snap-in relationship to the hanger section but wherein the parts providing the snap-in function are independent of the load bearing areas so that the snap-in relationship is not dependent upon such parts for carrying the cord guide, as pulley, loading.
5. To provide a cord guide support, as aforesaid, in which a single hanger section design may be utilized for a plurality of cord guide support designs in order to simplify the inventorying of such components.
6. To provide a cord guide support, as aforesaid, in which the parts can be assembled by a single motion and do not require the more complicated motions normally associated with hinge and pin arrangements.
Other objects and purposes of the invention will be apparent to persons acquainted with devices of this general type upon reading the following specification and inspection of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevational view of a pulley support embodying the invention and showing same in a position for suspension from a downwardly facing surface, such as a ceiling.
FIG. 2 is an end elevational view taken from the rightward end of FIG. 1 including also a showing of supporting means such as a ceiling and the relationship therewith of said pulley support.
FIG. 3 is a top plan view of the pulley support of FIG. 1.
FIG. 4 is a sectional view taken on the line IV--IV of FIG. 1.
FIG. 5 is a sectional view taken on the line V--V of FIG. 2.
FIG. 6 is a sectional view taken on the line VI--VI of FIG. 5.
FIG. 7 is a side elevational view of a pulley support assembly utilizing the same hanger member as shown in FIG. 1 but a different pulley support member.
FIG. 8 is a sectional view taken on the line VIII--VIII of FIG. 7.
FIG. 9 is a sectional view taken on the line IX--IX of FIG. 8.
FIG. 10 is an end view of the pulley support similar to FIG. 2 but showing the pulley support in a position of operation appropriate to mounting same on a vertical wall.
FIG. 11 is a side elevational view of a different embodiment of said pulley support.
FIG. 12 is an end view of the pulley support of FIG. 11 showing same in relationship with supporting means having a downwardly facing surface and showing in broken lines the capacity of the pulley housing thereof for swinging with respect to the hanger section thereof.
FIG. 13 is a top plan view of the pulley support shown in FIG. 11.
FIG. 14 is a section shown on the line XIV--XIV of FIG. 12 but eliminating therefrom the showing of the supporting structure.
FIG. 15 is a section taken on the line XV--XV of FIG. 11 and showing same mounted upon a vertical supporting surface such as a wall.
FIG. 16 is a side elevational, partially broken, view of a still further modified structure.
FIG. 17 is an end elevational view of the structure of FIG. 16 showing in broken lines therein the capacity of the pulley housing for swinging with respect to the hanger section.
DETAILED DESCRIPTION
Referring now to the drawings in more detail, there is shown in FIGS. 1-5 a cord guide, here pulley, support assembly comprising a hanger section 1 and a pulley housing 2. The hanger section 1 is arranged for fixing rigidly as by screws to support means, such as the ceiling 5 adjacent the upper end of a liftable shade, and the pulley housing is pivotally connected thereto for swinging motion as indicated by the arrows A and B in FIG. 2.
First examining the hanger section in more detail, there is a body or plate member 3 having a central opening 4 therein for purposes appearing hereinafter. Openings 6 are provided as desired for the entry of screws to fix the pulley hanger to a supporting surface, such as a ceiling. Short projections 7 are provided if desired for firmly holding the hanger rigidly with respect to the supporting surface and preventing its twisting, especially during installation.
Depending from the plate member 3 are trunnion hangers 8 and 9 which carry on their mutually facing surfaces the trunnions 11 and 12, same defining upwardly facing, convex, trunnion surfaces. There are of semicircular cross section and are fixed with respect to, here molded integrally with, the trunnion hangers 8 and 9.
Reinforcing members 13 are provided at both ends of the hanger member as desired and provide reinforcing between the plate member 3 and the trunnion hangers 8 and 9. Trunnion guards 14 and 16 extend downwardly from the plate 3, extend between the trunnion hangers 8 and 9 and are spaced at their lowermost extermities sufficient distances 14A and 16A from the trunnions 11 and 12 to provide for the passage therebetween of the pulley housing trunnions as hereinafter described. The trunnion guard 16 may be somewhat shortened as compared to the trunnion guard 14 as shown in FIG. 4 for purposes appearing further hereinafter.
Now turning to the pulley housing 2, same comprises a generally U-shaped body portion or clevis 21 with a pulley 22 rotatably supported therein in any conventional manner such as by the shaft 23 projecting through suitable openings 24 and 26 in the side walls of said clevis. One end of said shaft may be upset as indicated at 27 for holding the pulley firmly in position. An opening 28 is provided in the bottom of the clevis for the passage of the shade cord and cord guides 29 may be provided across said opening 28 if desired. (Said cord guides will not generate appreciable, if any, friction with respect to the shade cords in view of the pivoting of the pulley as hereinafter described in more detail.) Further openings 31 are provided in horizontal alignment with the upper edge of the pulley 22 for the passage of the cords in the region of the pulley outwardly of said pulley housing toward the shade structure.
At the upper side of said clevis 21 at each horizontal end thereof there are provided the pulley trunnions 32 and 33, both having, in this embodiment, downwardly facing concave trunnion surfaces. Same are fixed with respect to, here molded integrally with, the adjacent portions of the clevis 21 and have portions thereof 32A and 33A extending beyond respectively corresponding ends of said clevis for overlapping, engaging with and being supported by, the support trunnions 11 and 12. The curvature of the respectively interengaging trunnions is, of course, substantially concentric to insure smooth operation although if desired the pulley support trunnions 32 and 33 may be designed on a radius slightly longer than that of the support trunnions to insure against binding therebetween.
The length of the pulley housing is such as to fit snugly between the mutually facing ends 11A and 12A of the support trunnions 11 and 12 and the distance between the respectively outer surfaces 36 and 37 of the housing trunnions 32 and 33 is such as to permit said housing trunnions to fit snugly but slidably between the end surfaces 38 and 39 of the opening 4. Thus, the pulley housing can be inserted into operative position merely by passing same through the opening 4 between the trunnions 11 and 12 until the housing trunnions 32 and 33 engage in supporting relationship said hanger trunnions 11 and 12.
If desired, cam-shaped projections 41 and 42 may be provided to provide a snap-in relationship between the hanger 1 and pulley housing 2 for holding same together during the mounting procedure. If said cams 41 and 42 are sloped also on the lower side thereof as shown in the drawings, the parts may be taken apart by a reverse snapping motion to that above described for assembly.
Any desired locking mechanism may be provided for holding the shade cords in a fixed position. In the present embodiment same constitutes a sloped slot 51 with a knurled pin 52 positioned therein. Same will effect more positive operation if there are provided the teeth 53 along one side of said slot into which can fit the teeth 54 comprising the knurling of said pin.
In one use of this embodiment said hanger is supported, as shown in FIG. 2, from a ceiling adjacent the upper end of the shade with which same is used. Alternatively, however, with the trunnion guard 16 shortened as shown in the drawings, the clevis may be rotated 90° with respect to the plane of the plate 3 and said plate then fixed, as shown in FIG. 10, to a vertical wall adjacent the window with which the shade is used. In either case, the cords are introduced through the openings between the guards 29 over the pulley 22 and behind the pin 52 as shown in FIG. 5. When said cord is pulled downwardly, the pin 52 will release same and when said cord is permitted to move back upwardly, particularly if it is angled slightly rightwardly as shown in FIG. 5, it will engage said pin in the usual manner and cause same to lock the cord at the desired point against further upward movement. Likewise in either case, whether the plate 3 is positioned vertically or horizontally, the cords may be angled away from the wall adjacent the window with which the shade is being used and said clevis will pivot as needed away from the wall to maintain the plane of the pulley in alignment with the alignment of the cords. This will minimize any friction which would otherwise exist between the cords and the cord guides and still insure that the cords remain in proper operative position on the pulley. In this connection it will be evident that the openings 31 should be arranged as closely as possible to the center or centers around which said trunnions operate in order to insure that pivoting of the clevis with respect to the hanger will not generate undesired friction between said cords and the walls defining said openings 31.
FIGS. 7-9 illustrate the same base 1 utilized with a different form of pulley housing, such as that used intermediate the ends of a Roman shade. In this embodiment there is provided a clevis structure 61 for holding a pulley, same being rotatably mounted therein in generally the same manner as above described in connection with said pulley 22. Extending above said clevis is a hemicylindrical portion 56 having extensions 57 extending from each respective end thereof to constitute trunnions. Said trunnions engage the trunnions 11 and 12 of the base 1 in the same manner as above described for the engagement of the trunnions 32A and 33A with the base trunnions 11 and 12.
Trunnion guards 58 and 59 are provided similar to the trunnion guards 14 and 16 and in this case there is provided a cutout 62 if desired to enable the pulley housing to rotate sufficiently to assume a position such that the plane of its pulley is parallel with the plane of the plate 3. This enables this unit also to be wall mounted if desired as well as ceiling mounted in the same general manner as already illustrated with respect to the form of FIGS. 1-5.
This construction may also be snapped in and out of operative position in the same manner as above described for the form of FIGS. 1-5.
It will thus be understood that a single design of base 1 may be utilized with a variety of pulley housings as desired thus simplifying both manufacturing procedure and the inventorying thereof.
Referring now to the form of the invention shown in FIGS. 11-15, it will be seen that in this instance the base structure has a pair of concave upwardly opening trunnion supports which carry a pair of trunnions which in turn support the pulley housing.
Referring to these figures in more detail, the hanger section 71 here comprises a pair of base plates 73 and 74 positioned perpendicularly with respect to each other and fixed rigidly with respect to each other as by being integrally molded as a single unit. Said base plates have means such as openings 76 and 77 associated therewith for reception of screws or other means for fixing same to a downwardly facing surface as shown in FIG. 12 or to a vertical surface as shown in FIG. 15. A plurality, here two, protuberances 78 are provided for guide structure against an edge as shown in FIG. 12 or for reception into a slightly deformable sealing surface for rigidifying said hanger structure 71 with respect thereto.
Projecting from and between the base plates 73 and 74 are a pair of spaced trunnion supports 81 and 82, each having coaxial upwardly opening concave surfaces 83 and 84 (FIGS. 12 and 13). Said surfaces are curved on the same radius and are hence in alignment with each other.
Suspended from said hangers 81 and 82 is the cord guide, here pulley, housing 72. Same comprises a generally boxlike structure 86 having sides 87 and 88 parallel with and spaced from each other. Said sides are connected and positioned rigidly with respect to each other by ends 91 and 92 which are rigidly fixed, as by being molded integrally with, said sides 87 and 88. Said box structure 86 also includes a pair of fixed, as integrally molded, trunnions 89 and 90 extending from each end thereof and presenting downwardly facing convex surfaces which rest on the upwardly facing concave surfaces of the respective hangers 81 and 82. Said convex trunnion surfaces are curved on a slightly smaller radius than that of the concave hanger surfaces 83 and 84, as best shown in FIG. 12, in order to assure easy pivoting with respect thereto and avoidance of binding.
Roller and lock structure is provided here generally similar to that of FIGS. 1-5. In this instance, a roller 93 is mounted on an axle 94 which is fixed rigidly between and with respect to said sides 87 and 88. Same may be so fixed in any convenient manner as by upsetting as indicated at 96 (FIG. 15). As best shown in FIG. 14 the upper surface of said roller is aligned with or slightly above the upper surface 97 of one of the trunnions in order that a cord C guided thereby may lead out therefrom to the structure it is controlling.
Lock structure is also provided for said cord C which is the same as that above described in connection with FIGS. 1-5. Since same is identical to the structure already described in connection with FIGS. 1-5, a further detailed description is unnecessary and it is sufficient only to identify the parts thereof, namely the slot 101 having teeth 102 along one side thereof, the cord engaging knurled roller 103 and a small pinion 104 (FIG. 11) integral therewith for engaging the rack teeth 102. Thus, rotation of the knurled roller 103 by contact with a moving cord C will cause said pinion 104 to walk along the rack teeth 102 and assure movement of said lock in a proper direction for fixing or releasing same as desired and as determined by the direction of movement of said cord C.
In the form here shown, the stiffener 106 is of such thickness that it is not possible (see FIG. 15) for the pulley guide 172 to assume a position parallel with the base plate 73 and the design and use of the structure in question is such that such a positioning would seldom if ever be necessary. However, if even greater versatility is desired for this unit, said stiffener 106 may be made of slightly less thickness in the vertical direction as appearing in FIG. 15 and with such modification the pulley guide 72 can assume a position parallel with that of the base plate 73.
In FIGS. 16 and 17 is shown a unit corresponding to that of FIGS. 7-9 and used, for example, intermediate the ends of a Roman shade. If desired, the hanger portion 111 thereof may be identical with the hanger 71 or as shown in the drawing and as will be more common in actual use, same may be slightly shorter to accommodate a pulley housing 112 which is somewhat shorter than the pulley housing 72.
The hanger 111 is, however, excepting for its length, identical with the hanger 71 and hence needs no detailed description. The numerals used thereon are the same as the numerals of the hanger 71 with the letter "A" associated therewith.
Turning now to the pulley housing 112, same comprises a generally rectangular box including a pair of spaced parallel sides 113 and 114 having fixed, as integrally molded, trunnions 116 and 117 at the upper end, same presenting a pair of downwardly facing convex trunnion surfaces for engagement with and support by the upwardly facing concave surfaces 83A and 84A of hangers 81A and 82A. A brace member 118 is provided across the bottom thereof. A pulley 119 is rotatably mounted between said side members 113 and 114 in any convenient manner, such as by a pin 94A which is identical with and upset in the same manner (FIGS. 14 and 15) as the pin 94.
Again, here, the stiffener 106A is of sufficient thickness that the pulley housing 112 is not able to quite assume a position parallel with the base plate 73A inasmuch as such positioning is seldom needed in the ordinary use of this pulley unit. However, if it is desired to have the greater versatility of such positioning, then it is a simple matter to reduce the vertical (as seen in FIG. 16) dimension of the stiffener 106A and the pulley housing 112 will then have no difficulty in assuming a position parallel with the base plate 74A alternatively with its position parallel with the base plate 74A.
In the drawings and foregoing description, it will be noted that the cord guide means has throughout been referred to as usually a pulley, namely such as the pulleys 22, 65, 93 and 119. However, it will be recognized that such use of a pulley within the cord guide housing in each case is merely the preferable form of cord guide means for most instances and such cord guide means may instead of a pulley be a rigid guide without departure from the substance of the invention as appearing in any of the illustrated embodiments. Likewise the lock structure shown in connection with FIGS. 1-5 and 11-15, while effective and capable of good cooperation with the rest of the disclosed devices, is not critical in any specific form to the invention as set forth in any of several embodiments and same may be modified or omitted entirely excepting as hereinafter otherwise specifically claimed, without departure from the scope of the invention.
Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that further variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | Cord guide, such as a pulley, and support therefor, for use with a liftable shade, as a Roman shade or a venetian blind. There is provided a pivotally suspended cord guide support for use with a liftable shade which will suspend the cord guide in a pivotal manner so that the pull cords may be held for operation at a substantial angle with respect to the wall without diminishing their effectiveness in operating the shade. Specifically, the cord guide is supported within a generally conventional clevislike structure which has a specially constructed head end adapted for pivotal support on and by a ceiling or wall attachable bracket. With such pivotal support, the clevis and the cord guide carried thereby, while normally hanging parallel with the wall, can be angled away therefrom to permit greater ease in pulling of the shade cords but without diminishing the accuracy or effectiveness of said cords in the operating of the shade. A lock and guides for the shade cords may also be provided if desired. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a semiconductor process, and more particularly relates to a method of protecting a shallow trench isolation (STI) structure from damages in etching and/or cleaning and to a composite structure resulting from the same method.
[0003] 2. Description of Related Art
[0004] The major isolation structure applied to highly integrated semiconductor devices currently is the shallow trench isolation (STI) structure, which is generally fabricated by forming a trench in a semiconductor substrate and filling the trench with an insulating material. The STI structure is readily scalable and does not suffer from a bird's beak issue present in a local oxidation (LOCOS) process for forming field oxide isolation, thus being a more ideal type of isolation structure for sub-micron MOS processes.
[0005] FIG. 1 depicts a top view of a layout of a semiconductor device structure in the prior art, and FIG. 2 depicts a cross-sectional view of the same along the line A-A′. Referring to FIGS. 1 and 2 , a STI structure 102 is formed in the substrate 100 to define active areas 103 , conductive lines 104 are formed over the substrate 100 crossing over the STI structure 102 and the active areas 103 , and spacers 106 are disposed on the sidewalls of the conductive lines 104 .
[0006] In a MOS process, multiple etching and cleaning steps are conducted, such as the etching step for removing a cap layer and a hard mask layer, the pre-cleaning step done before a salicide layer is formed, the cleaning step conducted after the spacers 106 are formed, and the cleaning step conducted after the source/drain regions are formed, etc.
[0007] During the etching and cleaning, the upper portion of each STI structure 102 is damaged to form a recess 108 , which possibly has a depth of 800 angstroms or more. Certain wet-etching steps and cleaning steps, especially the pre-cleaning step before the salicide process, cause lateral corrosion to the STI structures 102 so that the recesses 108 extend to below the spacers 106 or even below the conductive lines 104 .
[0008] In a later deposition step for an inter-layer dielectric (ILD) layer (not shown), seams are formed in the ILD layer due to the presence of the recesses 108 . Meanwhile, the deposited material is difficult to fill in the parts of the recesses 108 under the spacers 106 so that there are still hollow spaces under the spacers 106 after the ILD deposition.
[0009] It is found that the seams in the ILD layer and the recesses 108 under the spacers 106 lower the isolation effect of the STI structure to cause current leakage. Moreover, in the step of forming tungsten contacts in the ILD layer, tungsten easily fills into the ILD seams and the hollow spaces under the spacers 106 due to its superior gap-filing capability, so that two neighboring tungsten contacts are easily shorted.
SUMMARY OF THE INVENTION
[0010] Accordingly, this invention provides a method of protecting a shallow trench isolation structure, which at least prevents two neighboring contacts from being shorted.
[0011] This invention also provides a composite structure resulting from the method of protecting a shallow trench isolation structure of this invention.
[0012] A method of protecting a shallow trench isolation structure of this invention is applied to a semiconductor device process that includes a first process causing a recess in the STI structure and a second process after the first process. The method includes formation of a silicon nitride layer in the recess along the profile of the same during the second process.
[0013] In an embodiment, the etching rate of the silicon nitride layer is lower than that of the STI structure. The STI structure may include silicon oxide.
[0014] In an embodiment, the first process includes an etching process or a cleaning process.
[0015] In an embodiment, the second process includes forming a salicide block layer for semiconductor devices isolated by the STI structure, and the salicide block layer and the silicon nitride layer are formed from the same silicon nitride base layer. In another embodiment, the second process includes forming spacers of semiconductor devices isolated by the STI structure, and the spacers and the silicon nitride layer are formed from the same silicon nitride base layer. In still another embodiment, the second process includes forming spacers of semiconductor devices isolated by the STI structure and forming a salicide block layer for semiconductor devices isolated by the STI structure, and the silicon nitride layer includes a first sub-layer and a second sub-layer, wherein the first sub-layer and the salicide block layer are formed from a first silicon nitride base layer, and the second sub-layer and the spacers are formed from a second silicon nitride base layer.
[0016] Another method of protecting an STI structure of this invention is applied to a semiconductor device process that includes forming a salicide block layer for semiconductor devices isolated by the STI structure and forming a salicide layer later. In the method, a protection layer is formed over the substrate covering the STI structure after the STI structure is formed but before the salicide block layer is formed, and then the portions of the protection layer not over the STI structure are removed. The etching rate of the protection layer may be lower than that of the STI structure. The protection layer may include silicon nitride, silicon-rich silicon oxide or silicon oxynitride.
[0017] The composite structure of this invention includes an STI structure in the substrate and a protection layer and is formed during a semiconductor device process, wherein the STI structure has a recess thereon and the protection layer covers the recess.
[0018] The protection layer may have a lower etching rate than the STI structure The STI structure may include silicon oxide. The protection layer may include silicon nitride, silicon-rich silicon oxide or silicon oxynitride.
[0019] In an embodiment, the protection layer and a salicide block layer formed for semiconductor devices isolated by the STI structure are formed from the same base layer in the semiconductor device process. In another embodiment, the protection layer and spacers of semiconductor devices isolated by the STI structure are formed from the same base layer in the semiconductor device process. In still another embodiment, the protection layer includes a first sub-layer and a second sub-layer, wherein the first sub-layer and a salicide block layer formed for semiconductor devices isolated by the STI structure are formed from a first base layer, and the second sub-layer and spacers of semiconductor devices isolated by the STI structure are formed from a second base layer.
[0020] In an embodiment, the surface of the recess is lower than that of the substrate so that at least a portion of the protection layer is located in a trench in which the STI structure is disposed.
[0021] Because a protection layer is disposed on the STI structure having a recess thereon, it is possible to prevent deepening and lateral extension of the recess in subsequent etching and cleaning, so that the isolation effect of the STI structure is maintained. Further, because the protection layer prevents extension of recesses on the isolation layer and thereby inhibits formation of seams in the ILD, two neighboring contacts are prevented from being shorted with this invention.
[0022] It is also noted that by integrating the forming steps of the protection layer with those of one or more other functional layers like salicide block layer and/or spacer, the semiconductor device process does not become more complicated.
[0023] In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, a preferred embodiment accompanied with figures is described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 depicts a top view of the layout of a semiconductor device structure in the prior art.
[0025] FIG. 2 depicts a cross-sectional view of the structure of FIG. 1 along line A-A′.
[0026] FIG. 3 depicts a top view of the layout of a semiconductor device structure at the start of a process flow for forming a protection layer on the STI structure according to a first embodiment of this invention.
[0027] FIGS. 4A-4C depict, in a cross-sectional view along the line B-B′ in FIG. 3 , the process flow according to the first embodiment of this invention.
[0028] FIG. 5 depicts a top view of a composite structure including an STI structure and a protection layer thereon according to a second embodiment of this invention.
[0029] FIG. 6 depicts a cross-sectional view of the composite structure of FIG. 5 along the line C-C′.
DESCRIPTION OF EMBODIMENTS
[0030] It is particularly noted that the above protection layer on the STI structure may be formed from an additional material layer that was never formed in the corresponding semiconductor device process of the prior-art, or alternatively be formed from one or more material layers used to form other functional layers in a semiconductor device process. In the latter way, the forming steps of the protection layer are integrated with those of one or more other functional layers in the semiconductor device process.
First Embodiment
[0031] FIG. 3 depicts a top view of the layout of a semiconductor device structure at the start of a process flow for forming a protection layer on the STI structure according to the first embodiment of this invention. FIGS. 4A-4C depict, in a cross-sectional view along the line B-B′ in FIG. 3 , the above process flow. In this embodiment, the forming steps of the protection layer are integrated with those of one or more other functional layers in a semiconductor device process.
[0032] Referring to FIGS. 3 & 4A , a substrate 200 is provided, with an STI structure 202 formed therein to define active areas 203 and conductive lines 204 formed thereon that cross over the isolation structures 202 and possibly include doped polysilicon. The STI structure 202 may include silicon oxide. The STI structure 202 and the conductive lines 204 can be formed with any suitable process in the prior art.
[0033] It is noted that after the STI structure 202 is formed, the etching step for defining the conductive lines 204 and a later cleaning step easily corrode the STI structure 202 to form therein recesses 205 each having a surface lower than that of the substrate 200 , which however do not affect the isolation effect of the STI structure 202 or make neighboring contacts formed later be shorted.
[0034] Referring to FIG. 4B , spacers 206 of the semiconductor devices isolated by the STI structure 202 are formed on the sidewalls of the conductive lines 204 that are also a part of the semiconductor devices, and simultaneously a protection layer 208 is formed in each recess 205 along the profile of the same. Since the surface of each recess 205 is lower than that of the substrate 200 , at least a portion of the protection layer 208 is disposed in the trench in which the STI structure 202 is disposed. The spacers 206 and the protection layer 208 are formed from the same base layer, and the protection layer 208 has a lower etching rate than the STI structure 202 . To form the spacers 206 and the protection layer 208 , it is possible to deposit a silicon nitride base layer over the substrate 200 through CVD and then etch back the same such that the portions thereof on the sidewalls of the conductive lines 204 and on the STI structure 202 are retained.
[0035] Referring to FIG. 4C , a protection layer 210 is formed on the STI structure 202 , and simultaneously a salicide block layer (not shown) is formed over the substrate 200 for some semiconductor devices isolated by the STI structure 202 . The salicide block layer and the protection layer 210 are formed from the same base layer, and the protection layer 210 has a lower etching rate than the STI structure 202 . To form the salicide block layer and the protection layer 210 , it is possible to deposit a silicon nitride base layer over the substrate 200 through CVD and then pattern the same such that the regions of the substrate 200 on which a salicide layer is to be formed are exposed, while the portions of the silicon nitride base layer on the STI structure 202 and on the regions of the substrate 200 not requiring salicide are retained.
[0036] It is particularly noted that when the two protection layers 208 and 210 together are considered as one protection layer, each of the two protection layers 208 and 210 is considered as a sub-layer of the one protection layer.
[0037] It is noted that though two protection layers 208 and 210 are successively formed over the STI structure 202 in the first embodiment, this invention is not limited to form two protection sub-layers but may alternatively form only one protection layer simultaneously with a functional layer like a salicide block layer or a spacer.
[0038] It is also noted that when only one protection layer is formed simultaneously with a salicide block layer in a later stage of a MOS process, the accumulative corrosion to the STI structure during previous steps makes a deeper recess thereon. In such a case, however, the protection layer still effectively ensures the isolation effect of the STI structure as being formed still before the pre-cleaning step prior to the salicide process which would damage an unprotected STI structure badly.
[0039] Accordingly, since a protection layer (possibly including two sub-layers 208 and 210 ) is formed on the STI structure 202 , it is possible to prevent deepening or lateral extension of the recesses on the same in subsequent etching and cleaning. Hence, the isolation effect of the STI structure can be maintained and neighboring contacts can be prevented from being shorted.
[0040] In addition, because the forming steps of the protection layers 208 and 210 are integrated with the inherent steps of a MOS process, the MOS process does not become more complicated.
Second Embodiment
[0041] FIG. 5 depicts a top view of a composite structure including an STI structure and a protection layer thereon according to the second embodiment of this invention. FIG. 6 depicts a cross-sectional view of the composite structure of FIG. 5 along line C-C′. In this embodiment, the protection layer is formed from an additional material layer never formed in the corresponding semiconductor device process of the prior art.
[0042] Referring to FIGS. 5-6 , a substrate 300 is provided with an STI structure 302 formed therein that defines active areas 303 . The STI structure 302 may include silicon oxide, and may be formed with any suitable process in the prior art.
[0043] A protection layer 304 is formed on the flat surfaces of the STI structure 302 , including a material having a lower etching rate than that of the STI structure 302 , such as silicon nitride (SiN), silicon-rich silicon oxide or silicon oxynitride (SiON). To from the protection layer 304 , it is possible to form a base layer (not shown) as a precursor thereof over the entire substrate 300 and then pattern the same to remove the portions thereof not over the STI structure 302 .
[0044] It is particularly noted that the protection layer 304 is formed immediately after the STI structure 302 is formed, so that the STI structure 302 is not damaged by subsequent etching or cleaning and can have a substantially flat surface.
[0045] In other embodiments, the protection layer formed from an additional material layer may not be formed immediately after the STI structure is formed, because the protection layer can ensure the desired functions of the STI structure if only it is formed before the pre-cleaning step prior to the salicide process which would damage an unprotected STI structure badly.
[0046] Because a protection layer is formed/disposed on the STI structure having a recess therein, it is possible to prevent deepening and extension of the recess in later etching and cleaning, so that the isolation effect of the STI structure is maintained. Further, because the protection layer prevents extension of the recesses in the STI layer, two neighboring contacts are prevented from being shorted. In addition, by integrating the forming steps of the protection layer with those of one or more other functional layers like a salicide block layer and/or a spacer, the semiconductor device process does not become more complicated.
[0047] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. | A method of protecting a shallow trench isolation structure is described, which is applied to a semiconductor device process that includes a first process causing a recess in the STI structure and a second process after the first process. The method includes forming a silicon nitride layer in the recess along the profile of the same during the second process. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and is a continuation of U.S. application Ser. No. 11/327,264, filed Jan. 7, 2006, which is a Continuation-in-Part of U.S. application Ser. No. 11/147,571, filed Jun. 8, 2005, the contents of both of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Numerous small vehicle jacks have been invented to deal with the necessity of raising vehicles smaller than typical automobiles, for purposes of performing repairs and other typical needs. Generally, the jacks have been specific as to what kind of vehicle they were adapted to.
[0003] Referring now to U.S. Pat. No. 4,066,243 (Johnson), a jack for the use with automobile bumpers is shown, in which a frame is provided as a support means for a vertical pipe, which has a sleeve, which moves upward and downward around said pipe. A typical floor jack provided the upward lifting force against the sleeve, where the floor jack was attached to the sleeve portion through a ring. This device required a secondary jack, and was limited to the lifting of a vehicle body parts which would comprise a bumper.
[0004] Referring now to U.S. Pat. No. 4,123,038 (Meyers), an apparatus is disclosed in which an elaborate load bearing frame is provided, where the apparatus operates using two separate hydraulic jacks. There is no realistic application of this type of device with a small tractor or riding lawn mower.
[0005] Portable jacks for small tractors are specifically exampled in U.S. Pat. No. 4,549,721 (Stone), in which a screw-scissors jack was operated to provide lifting force against a framework so as to push the framework upward. It would appear that one of the drawbacks of this invention was that the framework had a rectangular configuration, which would create a problem where a portion of the framework had to be moved under the tractor front wheels. This requirement would present a problem in a situation where the tractor was unable to move under its own power, requiring physical work to move the tractor over the framework assembly. Further, this device would not work properly at a location where the ground on which the tractor was situated was not properly leveled.
[0006] Referring now to U.S. Pat. No. 5,358,217 (Dach), the lifting apparatus is disclosed, in which a framework had a narrow front end, and avoided some of the problems inherent in the Stone patent referenced above. This system required a hydraulic cylinder to provide an upward pushing force to lift the item or vehicle. Extended arms had curved metal prongs that were referenced as lifting points. This jack was not intended for use with small tractor wheels, but rather were intended for axle assemblies.
[0007] Referring now to U.S. Pat. No. 6,330,1997 (McGaun et al.), a lifting apparatus for small vehicles is shown. The assembly uses pivoting action of its framework to first engage the wheels, and then lift the wheels by pivoting the framework so as to use a lever action to urge the wheels off of the ground.
[0008] Referring now to U.S. Pat. No. 6,474,626 (Box), a rack for securing a lawn mower to an elevated position is shown, in which a cage-like framework assembly is provided, and where a flexible webbing is used with a wheel crank to pull the entire lawn mower into an elevated position. This assembly is similar to an automobile rack, with the exception that the lifting framework is rectangular in nature, and supports all four wheels of a push mower on rack.
[0009] Further patents have disclosed jacking mechanisms with riding lawn mowers. U.S. Pat. No. 6,516,597 (Samejima et al.) discloses a lawn tractor which allows manipulation of its wheel supports into position so that they can be used to assist in raising up the front end of the lawn tractor.
[0010] Referring now to U.S. Pat. No. D 468,512 S (Hernandez), an all-terrain vehicle lift is disclosed, in which a hydraulic cylinder is used, to lift a metal framework that is disposed at the front end of the apparatus. The invention uses a rectangular frame, and a support means for the wheel is limited to a single tire, and not to two wheels, unless they are fairly close together.
SUMMARY OF THE INVENTION
[0011] From time to time, small tractors, riding lawnmowers, and other similar vehicles require maintenance requiring that one end of the vehicle be elevated. The use of hydraulic floor jacks do not always provide a single stable support structure, and jack stands are often the wrong size with regard to the elevation requirements for the small vehicles. In some situations, the angle of the vehicle necessary to accomplish the desired elevation of one end of the vehicle, makes the use of small jacks unwieldy, since small hydraulic system jacks only have a single contact point. As the contact point rotates by virtue of the elevation difference between the front and back end of the vehicle, the contact point with the hydraulic jack may become unstable. Further, the amount of elevation necessary will often exceed a hydraulic jack assembly's capability.
[0012] A complete apparatus is necessary, where the wheels of the vehicle may be used to elevate the entire end of a vehicle, rather than relying on the frame or other similar contact points available with typical hydraulic jacks for such a vehicle. A means to provide use of a jack with a stationary vehicle is desired, where the supporting structure can be moved into position on a vehicle, without requiring movement of the vehicle onto the jack means itself.
[0013] This invention comprises a small portable jack that is intended for use with small tractors, riding lawn mowers, four-wheel sport motorcycles, and other small vehicles. This small vehicle jack support system obviates the need for hydraulic systems, but instead uses a vertical jack bar with a winch system and flexible strap on top of the apparatus to provide the lifting force.
[0014] The jack itself has a base that defines a stable platform, also referred to as a support frame, that is intended to slide underneath the front end of the tractor or other vehicle. This jack may also be used on the back end of the tractor or other similar vehicle, but for purposes of discussion, the front end of the vehicle will be used as the example with the lifting method and apparatus for this invention.
[0015] The framework that contacts the ground is preferably a rectangular configuration, in which the main frame members comprise parallel side beams, a front cross member, and two rear cross members for additional strength. The rear cross members are typically parallel, and allow a mounting plate to be affixed thereto, using bolts, or any other typical attachment means, such as welding, clamping, or other means commonly known and understood in the art. A vertical frame bar is fixed to the mounting plate, and projects upward.
[0016] A lifting frame is provided, in which a center bar is connected at its front end perpendicularly to a cross bar member, where said cross bar member has a length that is equal to or greater then the width of the support frame from side to side. The crossbar and center bar define a T-shaped structure. The crossbar sits upon the support frame, with its ends resting on crossbar rest members, where the crossbar rest members define the widest portion of the support frame.
[0017] The center bar has a rigid guide member fixed to each side of the center bar rear end, where the guide members are slightly angled rearward from a 90 degree or perpendicular setting. Each guide member is spaced apart and parallel to each other, defining a gap that is at least as wide as the width of the center bar. The center bar preferably has a width greater than the vertical frame bar. As the guide members are parallel to each other, they allow the vertical frame bar to be positioned between them.
[0018] Once the lifting frame is positioned so that the vertical frame bar is situated between the angled guide members, a top roller is placed through its receiving apertures located on the terminating ends of the guide members, so that the vertical frame bar is restrained within the guide member gap area. A bottom roller is also positioned on the opposite side of the vertical frame bar, through the side guide members. The bottom roller, the parallel guide members and top roller function as a sleeve, which fits around the vertical frame bar, allowing the lifting frame to be moved upward and downward, with the gap between the guide members allowing some limited horizontal motion of the lifting frame. This allows for easy adjustment to the position of the lifting frame.
[0019] The vertical frame bar supports a winch means on its top end, with a flexible strap providing the pulling force necessary to lift the vehicle. In instances where the apparatus is desired to have height adjustment capability, a separate extension bar is provided, which allows the vertical bar, without any top structures attached, to be inserted into the extension bar.
[0020] The extension bar is provided, when greater height is desired, than can be obtained from a standard vertical frame bar. Also, the separate extension bar is provided for the simple need of disassembly and storage when so desired. Since both situations are generally desired, a extension bar is typically used with this apparatus.
[0021] The extension bar defines an inner cavity which allows the length of the vertical frame bar to be inserted completely into the extension bar. The extension bar preferably has a width similar to the center bar, with the gap defined between the guide members sufficient to allow said guide members to move freely over the extension bar.
[0022] The extension bar supports a platform which in turn supports a geared winch system that operates a flexible strap. The end of the flexible strap defines a hook, which is able to connect to a lifting ring located on the center bar, in proximity to the guide member attachment points with the center bar.
[0023] Removable wheel supports are provided, which are defined by a horizontal shaft, with a crossmember spacer which defines prongs on each end of the spacer, with the prongs defining a horizontal extension that is able to impact against the bottom side of a wheel. The prongs are spaced apart to define a gap, with the wheel able to rest between said gap. The wheel support assembly is attached to the crossbar by sliding the shaft into the inlet of said crossbar and securing the shaft and crossbar to each other.
[0024] Safety features also include axle guards, which comprise prongs that project upwards from the crossbar, and prevent the axle from slipping off of the crossbar when in use. These prongs are able to be removed when not needed, or able to be positioned as desired so that they are able to provide axle movement restriction as needed. The axle prongs may be fixed to a shaft sleeve, which allows the crossbar to be inserted through it, allowing the prong and shaft sleeve to move along the length of the crossbar, with the axle of the vehicle being lifted able to be secured as to movement against the axle prong.
[0025] Once the wheels of the vehicle are secured within the gap between the wheel support spacer prongs, the handle of the winch assembly is turned, causing the flexible strapped to move upward, thus exerting a lifting force against the lift ring. The lifting frame is raised vertically. The weight of the vehicle on the cross bar maintains the orientation of the lifting frame in a fairly horizontal position. The frame is unable to angle downward due to do the top and bottom roller. The strap is withdrawn until the lifting frame has raised the vehicle to the desired level. The winch is locked in position, using the braking systems commonly associated with such winch systems.
[0026] One advantage of having a separate extension bar is that the overall height capabilities of the jack can be varied, according to the length of the extension bar. Use of the strap denies the need for any type of hydraulic system, with the winch apparatus providing sufficient force to the strap, especially if the winch apparatus has a geared ratio with regard to the handle movement.
[0027] The jack assembly is portable, in the sense that the support frame defines wheel axles that are defined as outwardly protruding axles, that are positioned immediately above the rearmost ends of the side frame members of the support frame, and project outward laterally to the side above the support frame. Wheels are used, which have a radius that very closely equals the distance from the axle to the ground, when the main frame is on ground level. For maximum support and strength, the wheels do not contact the ground surface, when the jack is in use. However, if the front portion of the frame is elevated, rotating the frame about the axles, the frame is angled upward from the rear toward the front. As the frame is elevated at the front, the wheels remain stationary as to location, and as the frame pivots around the axles, not only the front portion of the frame is elevated off of the ground level, but the rearmost portion of the frame is also slightly elevated, allowing the supporting wheels to remain and the single contact points of the apparatus and the ground. The entire apparatus can be manipulated into position so that the center of gravity passes through the wheel axles, making the weight of the apparatus negligible, with regard to movement from one location to another. Once the apparatus is positioned with the center of gravity over the wheel axles, it can be easily rolled from one point to another by a single person.
DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of the improved small vehicle jack, in which the wheel support means and extension bar are shown in an exploded view.
[0029] FIG. 2 is a perspective view of the improved small vehicle jack in which the vertical frame bar and comprises the vertical support for the winch system.
[0030] FIG. 3 is a perspective view from above a riding lawn mower with the improved small vehicle jack positioned underneath it, with the tires of the riding mower positioned above the wheel support means.
[0031] FIG. 4 is a perspective view of the riding mower and vehicle jack, where the jack assembly has been moved to a raised position with the front end of the riding mower shown elevated.
[0032] FIG. 5 is an enlarged view of the sleeve assembly, showing the guide members and the top and bottom roller.
[0033] FIG. 6 is a side view of the sleeve means, in which the guide member is shown, with the lower and upper rollers shown, and where the safety pin is also shown.
[0034] FIG. 7 —withdrawn
[0035] FIG. 8 is a perspective view from above and from the left rear portion of the improved small vehicle jack frame and vertical member, showing the wheel axles without the wheels mounted thereon.
[0036] FIG. 9 is a side view showing the resting position of the frame and wheels, and the elevated position of the frame, in relation to the wheels.
[0037] FIG. 10 is a cross sectional view of the crossbar and axle hook means.
[0038] FIG. 11 is a perspective view of the crossbar and axle hook means, showing the relative position of an axle.
[0039] FIG. 12 is a perspective view of the jack showing the frame assembly and support guides in a lowered position.
[0040] FIG. 13 is a perspective view of the jack showing the frame assembly, with the crossbar in a raised position, with the support guides and cups supporting the crossbar.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Referring to FIG. 1 , the improved small vehicle jack apparatus 10 is shown. Said apparatus 10 is comprised of a support frame 15 , a lifting frame 60 , a lifting means 42 , and a wheel support means 50 . The support frame 15 is comprised of two generally parallel crossbar rest members 18 and 19 , which are spaced apart by a front member 20 . A further improved configuration is shown also in FIG. 8 , in which the support frame 15 is identical with regard to the front portion, where crossbar rest members 18 and 19 are separated by front member 20 , but where the rear portion of the crossbar rest members 18 and 19 are not angled, but maintain a generally straight configuration. As FIG. 8 depicts, the support frame 15 may also be defined by cross bar rest members 18 and 19 , which are spaced apart by front member 20 , and also spaced apart by back support members 71 and 72 , to form a rectangular configuration. In either configuration, members 18 , 19 and 20 , comprise the portion of the support frame 15 that is actually intended to be moved underneath the vehicle. Back support members 71 and 72 may comprise a single member, and should not be interpreted as being required as two separate members.
[0042] In the configuration shown in FIG. 1 , the crossbar rest members 18 and 19 are attached to the front member 20 ends, with angled members 13 fixed to the crossbar rest member 18 and 19 rear ends. The angled side members 13 are angled in relation to each other so that the distance between them becomes closer toward each other along their length from the front toward the rear. The rear ends of the angled side members 13 define end portions 25 that are fixed in relation to each other and which allow a vertical frame bar 14 to be fixed in a vertical position at the rear portion of the apparatus 10 .
[0043] As FIG. 8 shows, an axle 21 is provided, which is fixed to the rear end of this apparatus 10 , and which supports wheels 22 located on either side of said support frame 15 . The wheels 22 are fixed in such a manner that the rear portion of the support frame 15 is able to rest on the ground, with the wheels 22 providing ground contact for the rear portion of the support frame 15 if the apparatus 10 is tilted backwards. It should be understood however, that wheels 22 are not required, but are shown in FIGS. 2 and 3 as the preferred manner of construction, since wheels 22 provide for an ease of transportation, in which the support frame forward end is elevated, with the ground contact being borne solely by wheels 22 . This allows ease of movement of the entire apparatus 10 . Referring also to FIG. 9 , the side frame member 18 is shown with the axle 21 and wheel 22 shown. When at rest, the support frame 15 will be in contact with the ground surface. As the front end of the side frame member 18 is elevated at the front, the support frame 15 pivots around the axle 21 , and the entire support frame 15 pivots upward from the ground surface. The entire small vehicle jack 10 will be supported by the wheels 22 , and if the entire jack 10 is pivoted so that the center of gravity is directly over the wheels 22 , the effort to maintain the jack 10 off of the ground is minimized. Movement of the jack 10 is easily accomplished by allowing the wheels 22 to rotate around their axles 21 .
[0044] In both the configurations shown in FIGS. 1 , 2 and 3 , and that shown in FIGS. 8 , 12 and 13 , the gap between the rear end portions 25 of the support frame 15 should be wide enough so as to accommodate the center bar 16 of the lifting frame 60 , and any sleeve means utilized with said lifting frame 60 . As the configuration in FIGS. 8 , 12 and 13 show, there is no narrowing of the gap, since the side support members 18 and 19 remain parallel.
[0045] The fixed vertical frame bar 14 projects upward from the support frame 15 . In the configuration shown in FIGS. 8 , 12 and 13 , the vertical frame bar 14 is fixed to the rear support members 71 and 72 , which comprise the rearmost portion of the small vehicle jack apparatus 10 . As these Figures show, the vertical frame bar 14 is fixed to a support plate 73 , and where the support plate 73 is fixed to the rear support members 71 and 72 , using bolts 74 which are placed through bolt holes 75 in the support plate 73 and also through bolt holes 76 in the rear support members 71 and 72 . It should be understood that the vertical frame bar 14 may be fixed to the support plate 73 in any manner commonly known and understood in the art. Further, the support plate 73 is not required for this invention to operate, but rather the vertical frame bar 14 may be fixed to rear support members 71 and 72 individually or both, through any means commonly known and understood in the art. FIGS. 8 , 12 and 13 show an alternative configuration for the rear portion of the jack 10 , with regard to that shown in FIG. 1 . In all other aspects, the operation of the jack 10 is equivalent in all Figures regarding the manner of raising the lifting frame 60 .
[0046] As FIGS. 8 , 12 and 13 show, the crossbar rest members 18 are generally parallel to one another, and are spaced apart by the front member 20 on the front or forward end, and spaced apart at the back by rear support members 71 and 72 , to form a rectangular configuration. The rectangular configuration is but one of many possible configurations, and this invention should not be considered as being limited to a base having a rectangular configuration only.
[0047] FIGS. 12 and 13 further depict the means to support the lifting frame 60 , while it is in a raised position. This means allows additional safety of this invention while in use, in that the means to support the lifting frame provides a stationary support that does not rely on the integrity of any lifting force, but rather provides support underneath the item being elevated.
[0048] Said means comprises support guides 82 , which are defined as sleeves that pivot around a pivot bolt 86 , where said bolt is placed though a guide hole 85 , and also through frame hole 85 ′, securing the support guide to the cross bar rest member 18 . When not in use, the support guides 82 may be laid parallel to the crossbar rest member 18 , or taken away by removing the bolt 86 so as to allow the crossbar rest member 18 to be moved independent of the apparatus 10 .
[0049] The support guides 82 may comprise members that are adjustable as to length. Where said members are adjustable, the support guides 82 may comprise sleeves, which allow separate solid support guides 89 to be inserted into the sleeve support guides 82 , and are adjustable as to overall length using an adjustment pin 91 , which is inserted through the support guide 82 and one of several adjustment holes placed defined along the length of the solid support guide 89 . The adjustment pin 91 , when placed through the support guides 82 and solid support guides 89 will fix their position relative to each other, and also fix the combined overall length of the combination of both guides 82 and 89 . The top or distal end of the solid support guide 89 defines a cup 83 , which allows it to engage the underside of the item being lifted. Said cup 83 is fixed to the end of the solid support guide 89 . If the adjustable features of this supporting system are not used, but rather the support guides 82 are used without the solid support guides 89 , the cup 83 may be fixed to the top or distal end of the support guides 82 , or said cup 83 may comprise a removal piece, and have a bottom leg extension that is able to be inserted into the support guide 82 in a manner similar to that shown by the solid support guides 83 .
[0050] While FIG. 12 shows the support guides 82 in a down or rest position, FIG. 13 depicts the same guides 82 in a perpendicular configuration, with the solid support guides 89 shown extending out of the support guides 83 , and supporting the cross bar 17 of the lifting frame 60 . Since the support guides are secured to the crossbar resting members 18 , and are vertical, they are able to assist in supporting the weight of the vehicle or contrivance being lifted by the apparatus 10 , and provide a useful safety feature so that the lifting force is not wholly dependant solely on the strap 45 during the time that the frame 60 has lifted, and while waiting to be let back down.
[0051] FIG. 1 shows a separate extension bar 40 , which fits down over the vertical frame bar 14 . In one of the preferred embodiments, there is no separate extension bar 40 , but the support frame 15 and incorporated vertical frame bar 14 support the winch means 42 . As is shown in FIG. 2 , the vertical frame bar 14 is fixed to the rear ends 25 of the support frame 15 , and projects upward and supports a platform 41 and onto which a winch means 42 is provided. The winch means 42 is comprised of a spool, 62 , a winch support 43 that fixes the position of the spool 62 , and a handle 44 , whose manipulation causes a geared assembly to cause the spool 62 to turn to take up or let out the length of the strap 45 .
[0052] A flexible strap 45 is shown in FIG. 1 and in FIG. 2 , where said strap 45 is wound about the spool 62 , with its terminating end defining a hook 46 . The flexible strap 45 is fed off of the spool 62 , and a roller 66 is preferably provided at the edge of the platform 41 which supports the winch means 42 . The flexible strap 45 is not limited to any type of specific material, but could include any type of flexible material that has durability and strength in its resistance to stretching and/or breakage. The term “strap” should be understood to include chains, cables, straps of various material, cords, in any other type of flexible straps may be used, and will all function in virtually the same manner.
[0053] As is shown in FIG. 2 , the support frame 15 and incorporated vertical frame bar 14 comprise a general L-shaped configuration, where the total height of the apparatus 10 will always be consistent with the height of the vertical frame bar 14 and winch assembly 42 .
[0054] FIG. 1 shows an embodiment of the apparatus 10 in which the vertical frame bar 14 has the same configuration, except that it is much shorter in FIG. 1 than it is in FIG. 2 . In FIG. 1 , an extension bar 40 operates as an extender of the vertical frame bar 14 . The extension bar 40 may have any overall length desired by the operator of this apparatus 10 . In this manner, the interchangeability of various extension bars 40 with a single support frame 15 and vertical frame 14 , allows for a single support frame 15 to provide possibility for an apparatus 10 that has multiple choices of overall height as to the orientation of winch assembly 42 . The winch assembly 42 as described for FIG. 2 operates in the same manner as the winch assembly 42 in FIG. 1 . The winch assembly 42 may be detachable from the extension bar 40 , so that a single winch assembly 42 and support frame 15 may be used with extension bars 40 of various lengths to create a jack apparatus 10 of varied overall heights.
[0055] The lifting frame is comprised of a center bar 16 , which is attached at its front end to a crossbar 17 , where said crossbar and center bar form a T-shaped structure. The crossbar 17 preferably has a length that is equal to or greater then the distance defined by the separation of crossbar rest members 18 and 19 . The crossbar 17 is preferentially perpendicular to the crossbar rest members 18 and 19 , with the terminating ends of the crossbar 17 able to sit on top of the respective crossbar rest members 18 and 19 .
[0056] Wheel support means 50 are provided, which are shown as being detachable in FIG. 1 and in FIG. 2 . It should be understood, that the detachability of the wheel support means 50 is considered to be an optional and a more advanced feature, than if the wheel support means 50 was permanently attached and made a part of the terminating ends of the crossbar 17 .
[0057] As FIG. 1 shows, the wheel support means 50 is comprised of a main shaft 52 , which supports a spacer 53 , where said spacer 53 is oriented at 90.degree. from the shaft 52 to form a T-shaped configuration. Prongs 54 are attached at each end of the spacer 53 , and project outward away from the apparatus 10 . As FIG. 1 shows, the prongs 54 are defined and shown as L-shaped members, in which the horizontal portion of the prong 54 is lower than the spacer 53 and shaft 52 . This is a preferred embodiment, since the horizontal portion of the prongs 54 are able to rest on the ground, while the crossbar 17 of the lifting frame 60 rests on top of the support frame 15 .
[0058] The wheel support means 50 may be detachable from cross bar 17 , in which the shaft 52 of the wheel support means 50 has an outer dimension that is at least less than the dimensions defined by insert 51 , which comprises the opening into the interior of crossbar 17 . Shaft 52 is moved into insert 51 until a desired position is reached, at which time both the shaft 52 and cross bar 17 are secured to each other using a securing pin 70 , which is shown in use in FIG. 2 . Such securing pins are common in the art.
[0059] The lifting frame 60 , is fixed in position with regard to the vertical frame bar 14 , or where a extension bar 40 is used, fixed in position to the extension bar 40 through a sleeve means. Referring now also to FIG. 5 , a sleeve means comprises the rear end of center bar 16 , in which guide members 31 and 32 are secured to the sides of the center bar 16 , being secured at a slight rearward angle, as compared to a vertical position, so that the guide members 31 and 32 project both upwards, and slightly toward the rear.
[0060] The gap defined between the guide members 31 and 32 allow for placement of the vertical frame bar 14 , or the extension bar 40 where one is used, with a top roller 84 placed through the respective holes 33 defined on the ends of guide members 31 and 32 . Referring now also to FIG. 6 , a bottom roller 84 ′ is situated through the side guide members 31 and 32 , in the manner that the top roller 84 is, with the bottom roller 84 ′ positioned above the center bar 16 , but adjacent to the vertical frame bar 14 . The rollers 84 and 84 ′ allow the lifting frame 60 to move smoothly upward and downward along the length of the vertical bar 14 , or any extension bar 40 , where one is used. The vertical frame bar 14 , or the extension bar 40 , when so situated between the guide members 31 and 32 , will provide a guide that the lifting frame 60 can follow in a vertical manner.
[0061] Operation of the apparatus 10 is accomplished by attaching the hook 46 , which is located on the end of the strap 45 , to a lifting ring 47 , which is located on the center bar 16 . Lifting ring 47 is depicted as an inverted U-shaped member that is fixed to the top side of the center bar 16 . It should be understood that any manner of connecting the strap 45 to the center bar 16 is understood to be contained within this embodiment. The strap 45 may be tied, or use any other connector means commonly known and understand in the art.
[0062] Where the wheel support means 50 are not detachable, the apparatus 10 must be positioned and the small vehicle 81 moved over the lifting frame crossbar 17 until the wheels 80 of the vehicle are placed in between the wheel support prongs 54 . Referring now also to FIG. 3 , once the wheels 80 are in position, apparatus may be actuated so as to raise the vehicle 81 .
[0063] One clear advantage of wheel support means 50 being detachable, is that their relative position to the cross bar 17 can vary. This allows for a proper fit to a wide variety of mowers and small vehicle wheel bases, which may vary from vehicle to vehicle. By sliding the shaft 52 along the length of the insert 51 of cross bar 17 , the wheel support means 50 can position the outer side of the spacer 53 against the wheel 80 of the vehicle 81 . Since most small vehicles 81 are relatively light, the vehicle 81 is simply pushed or moved forward so that the wheels 80 are positioned between the prongs 54 . The wheel support means 50 is then adjusted as to width, to ensure the proper fit.
[0064] This apparatus 10 is also useful where the vehicle is difficult to move. Referring back again to FIG. 1 , that wheel supports 50 that are detachable, allow the wheels supports 50 to be independently placed around the wheels 80 of the vehicle 81 . Once the wheel support means 50 are jointly position, with their shafts 52 oriented toward each other, the support frame 15 and lifting frame 17 are slid underneath the front end of the vehicle 81 , until the crossbar 17 is positioned adjacent to the ends of the shafts 52 of each of the wheel support means 50 .
[0065] Shafts 52 are able to be moved into insert 51 and may be secured using pins 70 . This is a particularly advantageous operation, since small vehicles may not be movable under their own power, and the jack assembly 10 is able to be positioned so it can support the vehicle 81 without the vehicle 81 having to be moved at all.
[0066] The lifting of the vehicle 81 is accomplished as shown in FIGS. 3 and 4 . As FIG. 3 shows, the wheel support means are in the proper position, with the prongs 54 making ground contact. Other points of ground contact would likely comprise the front member 20 and wheels 22 . Activation of the winch means 42 , is accomplished by turning the handle 44 which causes the length of the strap 45 to be taken up by the spool 62 . The strap 45 conveys a pulling force through the hook means 46 to the lifting ring 47 which causes the center bar 16 to move upward.
[0067] As the center bar 16 , moves upward the weight of the vehicle 81 will be pressing downward on the wheel support means 50 . Movement of the center bar 16 will be limited to vertical movement, as a result of the restrictions applied by the guide members 31 and 32 and top roller 84 and bottom roller 84 ′. Top roller 84 and bottom roller 84 ′ will prevent the lifting frame 60 from tipping forward, as its forward movement will be prevented by the vertical frame bar 14 , or the extension bar 40 if one is used. Removal of the apparatus 10 from the vehicle 81 involves a reverse process, where the vehicle 81 is lowered to the ground, the wheel support means 50 are slid out of the crossbar 17 , and able to be removed from the vehicle area. The support frame 15 and lifting frame 60 are then pulled out from underneath the vehicle.
[0068] Referring now also to FIG. 10 and FIG. 11 , an axle hook means 90 is shown, comprising an outer sleeve 91 which has an inner perimeter opening 93 that corresponds to the outer surface of the cross bar 17 . The axle hook means 90 defines a top surface 94 , with an upwardly projecting prong 92 , with the axle hook means 90 able to slide along the length of the cross bar 17 until it is able to be positioned so as to allow the cross bar 17 to engage the axle 78 of a small vehicle. In this use, the wheel support means 50 may not be desired or used, and in the event that they are detachable, they can be removed during this process. The axle hook means 90 is placed over the end of the cross bar 17 , so that the cross bar 17 is disposed through the opening 93 . The projecting prong 92 preferably is fixed to the side of said outer sleeve 91 , and is L-shaped, with a portion of its length extending upwards above the top surface 94 , thus limiting the movement of any axle 78 past said prong 92 . Said prong 92 may also function as the supporting contact point with the axle 78 .
[0069] An additional safety feature is also shown FIG. 12 and FIG. 13 , in which the
[0070] From the foregoing statements, summary and description in accordance with the present invention, it is understood that the same are not limited thereto, but are susceptible to various changes and modifications as known to those skilled in the art and we therefore do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications which would be encompassed by the scope of the appended claims. | An apparatus configured to lift vehicles having various wheels bases and axle configurations is provided. The apparatus includes a vehicle jack which includes a support frame having a base portion and a lifting-frame-support portion. The vehicle jack also includes a lifting frame having a vehicle part engaging portion and a sleeve mounted adjacent the lifting-frame-support portion so that the sleeve moves along a path defined by the lifting-frame-support portion. The vehicle jack also includes a winch mounted adjacent to the support frame and a flexible member mounted adjacent to the winch so that when the lifting frame is in a first position and the winch is activated in a first direction, the winch moves the flexible member so that the flexible member exerts an upward force on the lifting frame. The upward force moves the lifting frame adjacent the lifting-frame support portion in an upward direction to a second position. | 8 |
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